CA2247957C - Coreless non-metallic filter element - Google Patents
Coreless non-metallic filter element Download PDFInfo
- Publication number
- CA2247957C CA2247957C CA002247957A CA2247957A CA2247957C CA 2247957 C CA2247957 C CA 2247957C CA 002247957 A CA002247957 A CA 002247957A CA 2247957 A CA2247957 A CA 2247957A CA 2247957 C CA2247957 C CA 2247957C
- Authority
- CA
- Canada
- Prior art keywords
- filter media
- support
- filter
- filter element
- wrap
- Prior art date
- Legal status (The legal status 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 status listed.)
- Expired - Lifetime
Links
- 239000000853 adhesive Substances 0.000 claims abstract description 30
- 230000001070 adhesive effect Effects 0.000 claims abstract description 30
- 239000000463 material Substances 0.000 claims abstract description 18
- 239000012530 fluid Substances 0.000 claims description 14
- 238000001914 filtration Methods 0.000 claims description 9
- 229920001169 thermoplastic Polymers 0.000 claims description 9
- 239000004416 thermosoftening plastic Substances 0.000 claims description 9
- 229920001410 Microfiber Polymers 0.000 claims description 6
- 239000003658 microfiber Substances 0.000 claims description 6
- 238000007789 sealing Methods 0.000 claims description 2
- 239000000057 synthetic resin Substances 0.000 claims description 2
- 229920003002 synthetic resin Polymers 0.000 claims description 2
- 239000002184 metal Substances 0.000 abstract description 11
- 238000011045 prefiltration Methods 0.000 abstract description 8
- 239000011324 bead Substances 0.000 abstract description 5
- 239000000835 fiber Substances 0.000 description 8
- 229920000728 polyester Polymers 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- 239000004593 Epoxy Substances 0.000 description 3
- 239000004677 Nylon Substances 0.000 description 3
- 229920001778 nylon Polymers 0.000 description 3
- 239000012260 resinous material Substances 0.000 description 3
- 238000003466 welding Methods 0.000 description 3
- 108091006146 Channels Proteins 0.000 description 2
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 2
- 229920005822 acrylic binder Polymers 0.000 description 2
- 101150087654 chrnd gene Proteins 0.000 description 2
- 238000000151 deposition Methods 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 125000006850 spacer group Chemical group 0.000 description 2
- 101100084503 Caenorhabditis elegans pas-3 gene Proteins 0.000 description 1
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 241001122767 Theaceae Species 0.000 description 1
- 230000004323 axial length Effects 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 235000021183 entrée Nutrition 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- -1 mel: bond Chemical compound 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- BULVZWIRKLYCBC-UHFFFAOYSA-N phorate Chemical compound CCOP(=S)(OCC)SCSCC BULVZWIRKLYCBC-UHFFFAOYSA-N 0.000 description 1
- 238000004382 potting Methods 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000012205 single-component adhesive Substances 0.000 description 1
- VWDWKYIASSYTQR-UHFFFAOYSA-N sodium nitrate Chemical compound [Na+].[O-][N+]([O-])=O VWDWKYIASSYTQR-UHFFFAOYSA-N 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/52—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material
- B01D46/521—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material
-
- 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
- B01D29/111—Making filtering elements
-
- 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
- B01D29/50—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 multiple filtering elements, characterised by their mutual disposition
- B01D29/56—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 multiple filtering elements, characterised by their mutual disposition in series connection
- B01D29/58—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 multiple filtering elements, characterised by their mutual disposition in series connection arranged concentrically or coaxially
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D39/00—Filtering material for liquid or gaseous fluids
- B01D39/14—Other self-supporting filtering material ; Other filtering material
- B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
- B01D39/2003—Glass or glassy material
- B01D39/2017—Glass or glassy material the material being filamentary or fibrous
- B01D39/202—Glass or glassy material the material being filamentary or fibrous sintered or bonded by inorganic agents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2411—Filter cartridges
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2201/00—Details relating to filtering apparatus
- B01D2201/04—Supports for the filtering elements
- B01D2201/0407—Perforated supports on both sides of the filtering element
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2265/00—Casings, housings or mounting for filters specially adapted for separating dispersed particles from gases or vapours
- B01D2265/06—Details of supporting structures for filtering material, e.g. cores
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2275/00—Filter media structures for filters specially adapted for separating dispersed particles from gases or vapours
- B01D2275/10—Multiple layers
Abstract
A coreless filter element (10) for a filter housing includes cylindrical filter media (20) having longitudinally-extending pleats extending from one end cap (22) on the filter media to another end cap (24) on the filter media. The filter media (20) is preferably a multi-layered structure with an outer support mesh layer attached to an inner prefiltration layer by an intermediate adhesive web layer. An inner wrap (64) of a porous fibrous filter media is provided within the central cylindrical cavity (58) of the pleated filter media (20). The wrap (64) has a cylindrical form with an outer surface which is joined to the inner pleat peaks of the media such as with adhesive applied in one or more beads, or as a continuous layer applied to the outer surface of the support wrap. The filter element (10) with inner support wrap (64) can be easily located over the metal support core (18) integral with the filter housing, and provides structural integrity for the pleats of the filter media. According to another embodiment, a series of circumferential bands formed from porous or imperforate material can be provided within the central cylindrical cavity (58) and joined by the adhesive to the inner pleat peaks of the filter media.
Description
Title of Invention CORELESS NON-METALLIC FILTER
ELEMENT
The present invention relates generally to filter elements, and more particularly, to a coreless filter element, that is, a filter element which can be located over a rigid support core integral with the filter housing, and can be removed from the support core and replaced when the filter element becomes used or spent.
Some filter elements include a perforated rigid support core surrounded by tubular or cylindrical fibrous filter media. Imperforate rigid plastic or metal end caps are typically located at opposite ends of the filter media, and at least one of the end caps has a central opening to allow fluid to flow into or out of the inner cavity of the filter element. The filter element can be located in a filter housing, with the element locators (fluid passages) in the housing received in the openings) in the end caps. In some instances, the filter media is pleated, that is, the filter media is formed with longitudinally-extending pleats extending from end cap to end cap. The pleats provide for a larger surface area in contact with fluid to be filtered, and hence increase the particle separation efficiency of the filter element. Fluid to be filtered either passes radially inward through the filter media and then outwardly through the opening in the end cap, or inwardly through the opening in the end cap and then radially outward through the filter media.
The support core for the filter element generally provides support for the pleated filter media, although certain filter media structures have been developed whereby the filter material is of such a rigidity that it is self supporting. Self supporting filter elements can require relatively thick media layers, epoxy-coated steel mesh layers, deep grooves in the exterior surface to increase the surface area, shallow pleat configurations, and/or a high resin content, all of which can increase the complexity, time, and cost associated with manufacturing the filter element. Self-supporting filter elements are therefor not appropriate for all filter applications. As such, many applications require a central support core for support of the filter media.
Applicants believe that filter elements with a central support core have typically been manufactured with the core formed integrally with the housing, that is, with the core fixedly attached to the surrounding filter media, such as by attachment to the opposing end caps (see, e.g.,Patent Specification US-A-4,033,881). As such, when the filter element becomes clogged or spent, the entire element, with support core, must be removed and replaced.
Many fibrous filter elements are not designed to be cleaned and reused, and as such, must be disposed of in an appropriate location, such as in a landfill. The support core is not easily removed from the filter media, and as such, the core is disposed of at the same time. These two components (filter media and core) take up valuable space in landfills. Additional disposal issues can be raised when the support core is formed from a non-combustible material, such as metal, which can require the use of expensive compacting machinery for proper disposal. Moreover, the replacement filter element has costs (labor and material) associated with both the fresh filter media and the support core, particularly if the core is metal.
Certain filter elements have been developed in an attempt to separate (remove) the spent filter media from the support core when the filter media is replaced. These "green" filter elements include, for example, Patent Specification US-A-5,476,585 to Mills, which shows a permanent metal support core in the housing surrounded by a removable pleated filter element. A spiral wrap is disposed around the exterior surface of the filter media to provide resistance against axially-directed forces. End cap portions on the filter media and on the core are fluidly sealed together and can be separated to remove the spent filter media from the core. Patent Specification US-A-4,211,543 to Tokar, et al., also shows a pleated filter media having an outer liner supporting the outer pleat peaks of the media. This reference also discloses that the filter media can be slid onto a conically-shaped safety sleeve assembly, which has been initially located over a rigid support core. Patent Specification US-A-5,211,846 to Kott et al., discloses to provide circumferential straps around the exterior of the coreless filter element to maintain the cylindrical shape of the filter media and to maintain separation of the pleats. On the other hand, Patent Specification US-A-5,413,712 to Gewiss et al., discloses to locate pleated (zig-zag) filter media directly over a rigid support core with no external wrap.
While the Mills, Tokar, Kott and Gewiss patents appear to allow the filter media to be removed from a support core permanently affixed to the filter housing, it is believed that the filter media can be difficult to locate over the core, particularly if the filter media is pleated because the inner peaks of the pleats can become distended or bent when the filter element is closely received over the support core. Further, the pleated filter media requires some structure to hold the pleats in fixed, closely-held relation with one another such that "lay-over", i.e., the folding over of the pleats against one another, is prevented. While the Mills, Tokar and Kott patents teach to provide an exterior wrap around the pleats, wrapping the exterior surface, particularly with a helical or spiral wrap, can be time-consuming and require significant amounts of wrap material. An exterior wrap can also have issues with appearance. The Gewiss patent, on the other hand, does not provide an outer wrap, and so can be unacceptable for many applications where a significant pressure drop across the element is expected.
As such, it is believed that the prior known designs for filter elements have not provided a coreless filter element which can be simply and easily located over a support core in the housing and removed from the housing when spent and replaced, which has a filter media structure which maintains the structural integrity of the pleats during use, and which is relatively simple and cost-effective to manufacture. Moreover, it is believed that there is a demand in the industry for a coreless filter element which does not have an outer wrap around the pleats, does not incorporate the drawbacks associated with many of the "self supporting" types of filter elements, and which can be easily disposed of in landfills.
According to one aspect of the invention there is provided a coreless filter element.
comprising cylindrical filter media having longitudinally-extending pleats extending from one end of i~C~. vtW:E'f'.A-vllE:'.,c:Hl-:'~: ly? :.3- F;-CA 02247957 1998-08-28 ylE~tyy~~~>-?-~ l,~y ~c,~ _':~~),~3~q.f;~:~s r t'ze filter media to another end of tire filter media. 'fhe pleats have closed ends, open ends, and opposing sidewalk extendins between respective closed ends and open ends which define outwardly-openin a pleat cavities around the alter element. A radially-inner surf'are of the c:osed ends of the ple:~ts defines ;~ central, Songitudinally-extending cylindricaS
cavity :vithin t_hr filt;.r media, and an inner cylindrical support wrap formed from a Iayei of porous;
f>~ruus filter media is disposed within the central cavity and has a radially outer surfarx joined u~ the radially-inntr surface c~f the closed ends of t_he pleat.
A new and unique careless filter element in such an arrangement cari be located over a rigid support core integral with the filter housing, and can ix easily removed from the support iv core and replaced when the filter element becomes spent or used. The falter element has filter media wi,h a structtue whiah~ maintains its stnictural intxgrity during use.
without the need for as outer wrap, arid whiarh is relativtrly simple and cost-affective to manufacture. The filter element dry iv~t incorporate metal components, which thereby a:la~x~s the element to be disposed of in conunercial landfills such as by biodegration or incin:ration.
Ac:.ording to thr prirxiples of flue present invention, thz .~'tlcer ,.lenient comprises cylin:irical titter rne<iia haring longiNdi.:.~allv-extending pleats extending from one er~u ef the filter media to the other e:td Impat~forate plastic end caps are disposed at each end of the filter media. According ca otu; embodiment, a suppeni~ slx~et comprising an i.rtner cylindri~a:
support wrap of a porous, fibrous niter ir~edia is disposed centrally ~~ithirmhe filter media and 3C has an outer surface which is joined to ttt$ inner peaks o: thin pleats.
The support wrap is preferably a non-woven polyester or other spun-bonded material, and which is bonded direvaly to the itu~er peaks su:h as by adltesiv~ applied in one or mare beads i5n the outer surfa;x of the wrap, or in a layer across the entire surfarx of the wrap. The support wrap preferably extends slang substantially the entire length o~ the filter m:;dia between the end caps arid fixidly :ocatea 2S the pleats with respact to one another for struztural integrity. The support wrap also allows the filter element to 'tic easily slid onto or off of a rigid support core w i.thout damaging, the pleated media.
:~C.'t. ~W ~:f:f'.~1-ttl t~:'~C.'H(:\ ~r_~ , a- r.>CA 02247957.1998-08-28 ',lr~~rp4tn?7- .,.9.~) H;~ ~3~~,~e.~:~ g s 'lfie alter element of the present i_nvetttiora is also re?atively easy to tnanufacw;a:: with an rnnsr support wrap. The support wrap is preferably ir:rtially 3isposed over a zziandrel, with the Side edges of the support wrap being overlapped. Adhesive is then applied arc:und the cute:
surface of the support wrap in one or more beads, or in a layer .across the entree ssa'ace. Tee 7 :;J::'.l~ilIrC1 filter media is then located over the sspport wrap in a c_rl.indriCal form, with the inner pleat peaks being adlxeaiveiv joined to the suppot'r wrap. The side edges of the fiker media a_re then att:~ch~d together using. e.g,., a hand or ribbon of adhesive.
The end caps are :hen located or opposite ends of the filter element t4 provide additional structural integrity for the fia~r element, acrd allots the filter element to be lo::ated within tl'~.e eletuent locators in the ! 0 filter housing.
According to another embo:i;rnent of the present invention, the suppartit~g sheet comprises op:: or more support band, disposed around tht irurer circumference of the pleated tiher media. Prefe:3i71y tli:ee bands are provided, with one band located close to each end of the filter media. acrd with the remaining band :~t about the ttxidpaint of the filter media. The I s bands each comprise w strip preferably fort,?; d from an imperforFtte mat~riul, such as n~rlon, but cart also be fortned f cm fibrous filter rnateriat similar to the support wrap. The bands are bondes to the inner pleat peaks by adhesive applied to the outer surface of the bands, and can extern ir. an annalas around L".~ intzer peaks of the pleats, or in a spiral er helical fashion.
In either of the embodiments described above, the inner support t~~rap or bands provide 2o structural integrity for the pleats and allow the filter clement to be eerily manufactured using common to ;hniqu~. The wrap or bard also allow tile falter element to be easily locac~d over a support core integral with a filter housing, and ratnoved front rt:e core and replaced when the filter element becomes used or spent.
The filusr media of the present invetaion is preferably a tn~,~ltilaye:ed fuser media 25 structure. Specifically, th: filter media preferably has an outer support mes>: layez, an a~ihes=ve ~;rb laye:, a nucao8ber capacity layer (prefiltratioa iayerj, a mictofiber ftltratron layer, and finally, an iruier support m:,sh layer, all disposed in adjacent, surface-to-surface contact with one another. The adhesive web layer is preferably a non-woven, polyester-based thermoplastic which joins the outer support mesh layer to the prefiltration layer and also provides structural integrity for the pleated structure of the filter media when the filter media is under pressure. This preferred filter media structure can be disposed of in a landfill such as by biodegration or by incineration. While one preferred form of the filter media structure is thus described, it should be apparent that the filter element can be used with other types of pleated filter media structures, as should be apparent to those skilled in the art.
As such, the present invention provides a filter element which can be simply and easily located over a support core integral with the filter housing, and easily removed and replaced when the filter element is spent. The filter element has a filter media structure which maintains the structural integrity of the pleats during use, and which is relatively simple and cost-effective to manufacture. Further, the filter element is formed from biodegradable or combustible components which allow the filter element to be relatively easily disposed of in commercial landfills without significant expense, such as without the use of expensive compacting machinery.
The invention is diagramatically illustrated by way of example in the accompanying drawings in which:
Figure 1 is a left end view of a filter element constructed according to the principles of the present invention, the right end view being smaller;
Figure 2 is a cross-sectional side view of the filter element taken substantially along the plane described by the lines 2-2 of Figure 1, illustrating the filter element disposed between opposite element locators in a filter housing and showing a first embodiment of the filter element with inner support wrap;
Figure 3 is a cross-sectional side view taken substantially along the plane described by the lines 3-3 of Figure 2, illustrating the pleat section of the filter element;
Figure 4 is an enlarged cross-sectional view of one of the end cap structures of the filter element of Figure 2;
ELEMENT
The present invention relates generally to filter elements, and more particularly, to a coreless filter element, that is, a filter element which can be located over a rigid support core integral with the filter housing, and can be removed from the support core and replaced when the filter element becomes used or spent.
Some filter elements include a perforated rigid support core surrounded by tubular or cylindrical fibrous filter media. Imperforate rigid plastic or metal end caps are typically located at opposite ends of the filter media, and at least one of the end caps has a central opening to allow fluid to flow into or out of the inner cavity of the filter element. The filter element can be located in a filter housing, with the element locators (fluid passages) in the housing received in the openings) in the end caps. In some instances, the filter media is pleated, that is, the filter media is formed with longitudinally-extending pleats extending from end cap to end cap. The pleats provide for a larger surface area in contact with fluid to be filtered, and hence increase the particle separation efficiency of the filter element. Fluid to be filtered either passes radially inward through the filter media and then outwardly through the opening in the end cap, or inwardly through the opening in the end cap and then radially outward through the filter media.
The support core for the filter element generally provides support for the pleated filter media, although certain filter media structures have been developed whereby the filter material is of such a rigidity that it is self supporting. Self supporting filter elements can require relatively thick media layers, epoxy-coated steel mesh layers, deep grooves in the exterior surface to increase the surface area, shallow pleat configurations, and/or a high resin content, all of which can increase the complexity, time, and cost associated with manufacturing the filter element. Self-supporting filter elements are therefor not appropriate for all filter applications. As such, many applications require a central support core for support of the filter media.
Applicants believe that filter elements with a central support core have typically been manufactured with the core formed integrally with the housing, that is, with the core fixedly attached to the surrounding filter media, such as by attachment to the opposing end caps (see, e.g.,Patent Specification US-A-4,033,881). As such, when the filter element becomes clogged or spent, the entire element, with support core, must be removed and replaced.
Many fibrous filter elements are not designed to be cleaned and reused, and as such, must be disposed of in an appropriate location, such as in a landfill. The support core is not easily removed from the filter media, and as such, the core is disposed of at the same time. These two components (filter media and core) take up valuable space in landfills. Additional disposal issues can be raised when the support core is formed from a non-combustible material, such as metal, which can require the use of expensive compacting machinery for proper disposal. Moreover, the replacement filter element has costs (labor and material) associated with both the fresh filter media and the support core, particularly if the core is metal.
Certain filter elements have been developed in an attempt to separate (remove) the spent filter media from the support core when the filter media is replaced. These "green" filter elements include, for example, Patent Specification US-A-5,476,585 to Mills, which shows a permanent metal support core in the housing surrounded by a removable pleated filter element. A spiral wrap is disposed around the exterior surface of the filter media to provide resistance against axially-directed forces. End cap portions on the filter media and on the core are fluidly sealed together and can be separated to remove the spent filter media from the core. Patent Specification US-A-4,211,543 to Tokar, et al., also shows a pleated filter media having an outer liner supporting the outer pleat peaks of the media. This reference also discloses that the filter media can be slid onto a conically-shaped safety sleeve assembly, which has been initially located over a rigid support core. Patent Specification US-A-5,211,846 to Kott et al., discloses to provide circumferential straps around the exterior of the coreless filter element to maintain the cylindrical shape of the filter media and to maintain separation of the pleats. On the other hand, Patent Specification US-A-5,413,712 to Gewiss et al., discloses to locate pleated (zig-zag) filter media directly over a rigid support core with no external wrap.
While the Mills, Tokar, Kott and Gewiss patents appear to allow the filter media to be removed from a support core permanently affixed to the filter housing, it is believed that the filter media can be difficult to locate over the core, particularly if the filter media is pleated because the inner peaks of the pleats can become distended or bent when the filter element is closely received over the support core. Further, the pleated filter media requires some structure to hold the pleats in fixed, closely-held relation with one another such that "lay-over", i.e., the folding over of the pleats against one another, is prevented. While the Mills, Tokar and Kott patents teach to provide an exterior wrap around the pleats, wrapping the exterior surface, particularly with a helical or spiral wrap, can be time-consuming and require significant amounts of wrap material. An exterior wrap can also have issues with appearance. The Gewiss patent, on the other hand, does not provide an outer wrap, and so can be unacceptable for many applications where a significant pressure drop across the element is expected.
As such, it is believed that the prior known designs for filter elements have not provided a coreless filter element which can be simply and easily located over a support core in the housing and removed from the housing when spent and replaced, which has a filter media structure which maintains the structural integrity of the pleats during use, and which is relatively simple and cost-effective to manufacture. Moreover, it is believed that there is a demand in the industry for a coreless filter element which does not have an outer wrap around the pleats, does not incorporate the drawbacks associated with many of the "self supporting" types of filter elements, and which can be easily disposed of in landfills.
According to one aspect of the invention there is provided a coreless filter element.
comprising cylindrical filter media having longitudinally-extending pleats extending from one end of i~C~. vtW:E'f'.A-vllE:'.,c:Hl-:'~: ly? :.3- F;-CA 02247957 1998-08-28 ylE~tyy~~~>-?-~ l,~y ~c,~ _':~~),~3~q.f;~:~s r t'ze filter media to another end of tire filter media. 'fhe pleats have closed ends, open ends, and opposing sidewalk extendins between respective closed ends and open ends which define outwardly-openin a pleat cavities around the alter element. A radially-inner surf'are of the c:osed ends of the ple:~ts defines ;~ central, Songitudinally-extending cylindricaS
cavity :vithin t_hr filt;.r media, and an inner cylindrical support wrap formed from a Iayei of porous;
f>~ruus filter media is disposed within the central cavity and has a radially outer surfarx joined u~ the radially-inntr surface c~f the closed ends of t_he pleat.
A new and unique careless filter element in such an arrangement cari be located over a rigid support core integral with the filter housing, and can ix easily removed from the support iv core and replaced when the filter element becomes spent or used. The falter element has filter media wi,h a structtue whiah~ maintains its stnictural intxgrity during use.
without the need for as outer wrap, arid whiarh is relativtrly simple and cost-affective to manufacture. The filter element dry iv~t incorporate metal components, which thereby a:la~x~s the element to be disposed of in conunercial landfills such as by biodegration or incin:ration.
Ac:.ording to thr prirxiples of flue present invention, thz .~'tlcer ,.lenient comprises cylin:irical titter rne<iia haring longiNdi.:.~allv-extending pleats extending from one er~u ef the filter media to the other e:td Impat~forate plastic end caps are disposed at each end of the filter media. According ca otu; embodiment, a suppeni~ slx~et comprising an i.rtner cylindri~a:
support wrap of a porous, fibrous niter ir~edia is disposed centrally ~~ithirmhe filter media and 3C has an outer surface which is joined to ttt$ inner peaks o: thin pleats.
The support wrap is preferably a non-woven polyester or other spun-bonded material, and which is bonded direvaly to the itu~er peaks su:h as by adltesiv~ applied in one or mare beads i5n the outer surfa;x of the wrap, or in a layer across the entire surfarx of the wrap. The support wrap preferably extends slang substantially the entire length o~ the filter m:;dia between the end caps arid fixidly :ocatea 2S the pleats with respact to one another for struztural integrity. The support wrap also allows the filter element to 'tic easily slid onto or off of a rigid support core w i.thout damaging, the pleated media.
:~C.'t. ~W ~:f:f'.~1-ttl t~:'~C.'H(:\ ~r_~ , a- r.>CA 02247957.1998-08-28 ',lr~~rp4tn?7- .,.9.~) H;~ ~3~~,~e.~:~ g s 'lfie alter element of the present i_nvetttiora is also re?atively easy to tnanufacw;a:: with an rnnsr support wrap. The support wrap is preferably ir:rtially 3isposed over a zziandrel, with the Side edges of the support wrap being overlapped. Adhesive is then applied arc:und the cute:
surface of the support wrap in one or more beads, or in a layer .across the entree ssa'ace. Tee 7 :;J::'.l~ilIrC1 filter media is then located over the sspport wrap in a c_rl.indriCal form, with the inner pleat peaks being adlxeaiveiv joined to the suppot'r wrap. The side edges of the fiker media a_re then att:~ch~d together using. e.g,., a hand or ribbon of adhesive.
The end caps are :hen located or opposite ends of the filter element t4 provide additional structural integrity for the fia~r element, acrd allots the filter element to be lo::ated within tl'~.e eletuent locators in the ! 0 filter housing.
According to another embo:i;rnent of the present invention, the suppartit~g sheet comprises op:: or more support band, disposed around tht irurer circumference of the pleated tiher media. Prefe:3i71y tli:ee bands are provided, with one band located close to each end of the filter media. acrd with the remaining band :~t about the ttxidpaint of the filter media. The I s bands each comprise w strip preferably fort,?; d from an imperforFtte mat~riul, such as n~rlon, but cart also be fortned f cm fibrous filter rnateriat similar to the support wrap. The bands are bondes to the inner pleat peaks by adhesive applied to the outer surface of the bands, and can extern ir. an annalas around L".~ intzer peaks of the pleats, or in a spiral er helical fashion.
In either of the embodiments described above, the inner support t~~rap or bands provide 2o structural integrity for the pleats and allow the filter clement to be eerily manufactured using common to ;hniqu~. The wrap or bard also allow tile falter element to be easily locac~d over a support core integral with a filter housing, and ratnoved front rt:e core and replaced when the filter element becomes used or spent.
The filusr media of the present invetaion is preferably a tn~,~ltilaye:ed fuser media 25 structure. Specifically, th: filter media preferably has an outer support mes>: layez, an a~ihes=ve ~;rb laye:, a nucao8ber capacity layer (prefiltratioa iayerj, a mictofiber ftltratron layer, and finally, an iruier support m:,sh layer, all disposed in adjacent, surface-to-surface contact with one another. The adhesive web layer is preferably a non-woven, polyester-based thermoplastic which joins the outer support mesh layer to the prefiltration layer and also provides structural integrity for the pleated structure of the filter media when the filter media is under pressure. This preferred filter media structure can be disposed of in a landfill such as by biodegration or by incineration. While one preferred form of the filter media structure is thus described, it should be apparent that the filter element can be used with other types of pleated filter media structures, as should be apparent to those skilled in the art.
As such, the present invention provides a filter element which can be simply and easily located over a support core integral with the filter housing, and easily removed and replaced when the filter element is spent. The filter element has a filter media structure which maintains the structural integrity of the pleats during use, and which is relatively simple and cost-effective to manufacture. Further, the filter element is formed from biodegradable or combustible components which allow the filter element to be relatively easily disposed of in commercial landfills without significant expense, such as without the use of expensive compacting machinery.
The invention is diagramatically illustrated by way of example in the accompanying drawings in which:
Figure 1 is a left end view of a filter element constructed according to the principles of the present invention, the right end view being smaller;
Figure 2 is a cross-sectional side view of the filter element taken substantially along the plane described by the lines 2-2 of Figure 1, illustrating the filter element disposed between opposite element locators in a filter housing and showing a first embodiment of the filter element with inner support wrap;
Figure 3 is a cross-sectional side view taken substantially along the plane described by the lines 3-3 of Figure 2, illustrating the pleat section of the filter element;
Figure 4 is an enlarged cross-sectional view of one of the end cap structures of the filter element of Figure 2;
Figure 5 is an enlarged cross-section the other of the end cap structures of Figure 2; and Figure 6 is a cross-sectional configuration of a filter element similar to Figure 2, but illustrating a second embodiment of the filter element with inner plural support bands.
Referring to the drawings, and initially to Figures 1-3, a filter element constructed according to the principles of the present invention is indicated generally at 10. The filter element is designed to be located within a filter housing of a filter assembly, and to receive at least one element locator of the filter housing. A pair of element locators are identified at 12 and 14 in Figure 2 disposed co-axial with one another at opposite ends of the filter element. Each element locator has a central fluid passage 15, 16, respectively, for directing fluid into or out of the filter 10 element. A perforated metal support core, indicated generally at 18, is attached to element locator 14 and extends centrally within the filter housing. As will be described herein in more detail, the support core 18 removably receives the filter element 10.
The filter element 10 includes a filter media structure, indicated generally at 20, which preferably has a cylindrical form with opposite ends enclosed by end caps 22, 24. One preferred structure for the filter media is a mufti-layered structure illustrated in Figure 3. This mufti-layered structure includes an outer support mesh or screen 30 formed from a thermoplastic synthetic resinous material, such as nylon or polyester, which can be woven or extruded.
Other conventional thermoplastic synthetic resinous material can also be employed for the outer support mesh, as should be known to those skilled in the art. In any case, the support mesh should have sufficient strength to withstand differential fluid pressure across the filter element.
A microfiber capacity layer 31, also referred to as a prefilter layer, is located inside of the outer support mesh 30. The prefilter layer increases the dirt holding capacity of the filter element, and preferably is formed from borosilicate microglass fibers with acrylic binder. Again, other conventional materials can be used for the capacity layer, as should also be known to those skilled in the art.
Referring to the drawings, and initially to Figures 1-3, a filter element constructed according to the principles of the present invention is indicated generally at 10. The filter element is designed to be located within a filter housing of a filter assembly, and to receive at least one element locator of the filter housing. A pair of element locators are identified at 12 and 14 in Figure 2 disposed co-axial with one another at opposite ends of the filter element. Each element locator has a central fluid passage 15, 16, respectively, for directing fluid into or out of the filter 10 element. A perforated metal support core, indicated generally at 18, is attached to element locator 14 and extends centrally within the filter housing. As will be described herein in more detail, the support core 18 removably receives the filter element 10.
The filter element 10 includes a filter media structure, indicated generally at 20, which preferably has a cylindrical form with opposite ends enclosed by end caps 22, 24. One preferred structure for the filter media is a mufti-layered structure illustrated in Figure 3. This mufti-layered structure includes an outer support mesh or screen 30 formed from a thermoplastic synthetic resinous material, such as nylon or polyester, which can be woven or extruded.
Other conventional thermoplastic synthetic resinous material can also be employed for the outer support mesh, as should be known to those skilled in the art. In any case, the support mesh should have sufficient strength to withstand differential fluid pressure across the filter element.
A microfiber capacity layer 31, also referred to as a prefilter layer, is located inside of the outer support mesh 30. The prefilter layer increases the dirt holding capacity of the filter element, and preferably is formed from borosilicate microglass fibers with acrylic binder. Again, other conventional materials can be used for the capacity layer, as should also be known to those skilled in the art.
Disposed between and immediately adjacent the inner surface of the outer support mesh 30 and the outer surface of the prefilter layer 31, is an adhesive web layer 32. The adhesive web layer preferably comprises a non-woven, polyester-based thermoplastic adhesive. The adhesive is heat sensitive and can be heat activated to i) join the outer support mesh to the capacity layer, and ii)facilitate maintaining the shape and structural integrity of the pleats after the web has thermally set. Preferable adhesive web material for the present invention is commercially available under model/designation Nos. SH 4200 and SH 4275 from Applied Extrusion Technologies, Inc. of Middletown, Delaware.
Immediately adjacent the inner surface of the capacity layer 31 is a microfiber filtration layer 36. The microfiber filtration layer is preferably comprised of the same material as the prefiltration layer, for example borosilicate microglass fibers with acrylic binder, but with a finer fiber or tighter structure than the prefiltration layer. Generally, the microfiber filtration layer defines the filtration efficiency of the filter element, and is generally about ten times the filtration efficiency of the prefiltration layer.
Immediately adjacent the inner surface of the filtration layer 36 is an inner support mesh layer 38. The inner support mesh layer 38 also preferably comprises the same material as in the outer support mesh layer 30, such as a thermoplastic synthetic resinous material which can be woven or extruded.
The thickness and porosity of the layers described above can vary depending upon the particular filtering application, and can be determined using simple experimentation. Further, as should be apparent to those skilled in the art, the preferred filter media structure described above is a combustible or biodegradable structure such that the filter media can be relatively easily disposed of in a commercial landfill. However, while the filter media structure 20 is preferably formed in the mufti-layered structure described above, it should be apparent to those of ordinary skill in the art that the filter media structure can have other known single or mufti-layered structures.
CA 02247957 1998-08-28,;f;~)f>4 W'.~ ~-~;) t~:~ _':;9'u-Et;;~: ~' r yt . t o'~.: t~f'a-t11 L:'(.'lIU\ u_~ . :3- E~-:)>3 . ,..~. z~ . _ _ in any case, rate filter media 2~ s preferab:y plated, that is, chc filter media includes axially-extending pleats ~xt<:n3ing from end cap 22 to end cap 24. Ea;,h pleat has a raciialiy outer pleat peak (ope:n end), sucJu as inriicat~ at 50, and a rsdi311y inner pleat peak (closed end), such zs indicated at ~2. Fach pleat atso includes sld~r~~alls, such as i1I115CraCed at >4 and 5~, which together with the outer pleat peaks SO arid inner pleat peaks ~~
define a series of radialty-outward opening pl=zt caviti;.s around the cirLsfnference of the filter element. 'phe cylindrical phated filter media also denn~s a cylindrical cavity, indicated genera.!ly a: ~R in Figure 1, centrally within the filter element. T'he techniques for piea:i;~ or corrugating the filter media are conve:ztioz~al in nature, and can include hand-forming or forming using a pleat machine.
To provide rigidity and structut~al ir_tegrity for the pleated filler media; a supporting sheet comprising an inner support wrap, it>dlcated xt b4 in Figures ? and 3, is dapc;sed wahin the cylindrical cavity of the filter element, Inner support wrap 64 prefera~yly comprises a porous, fibrous filter media of a non-woven thermoplastic syntheti:. rrsin, such as polyestEr.
The inner support wrap is preferably a :~p~un-boruied traterial. A "spun-bo:rde~" maceriai oan be prepared by depositing extruded thermoplastic synthetic resin filaments into a non-~NOVen mat while the filaments are in a soft or partially molten fot7n. The soft fibers generally th~rmalJy adh'rre to one ay~ather, i.e., mel: bond, and when ceateci, force an integra.i mass of non-woven fil3tnentary struc:ure. The iz~rter-support wrap can also be formed from spun-z~ bonded glass fibers, dltbough polyester fibers are preferred. Support wrap fr4 preferably has a permeability of at least tea times the perme~it:ty of the filte: media 10, and does not appreciably affect the pressure drop across the .filter element. As should be apparent from the above, the support wrap is also preferably formed from a combustible or ittci:neratnhle rnater:al, similar to the material forming the filter cn~dia, such that the composite, stnictura car. be z5 relatively easily incinerated or disposed of in a commercial landfill.
The support wrap 54 is formed in a cylindrical or tubutar fornr., with the outer surface of the suppor! wrap being joined to the in:oer pleat peaks 52 of the pleats.
Preferably, the ,upport wrap 6.~ is joined to tire inner pIe3t peaks by conventional adhesive which oan be applied to the outer surface of the support wrap in one or more beads (circumferentially or helically applied), or alternatively, applied continuously in a coating or layer across the entire outer surface of the support wrap. A layer of adhesive is indicated at 65 in Figure 3. The adhesive bonds the inner pleat peaks to the support wrap, which fixes the inner pleat peaks with respect to one another and 5 provides rigidity and structural integrity for the pleated filter media. The support wrap is of course unattached and is spaced from the filter media at the locations between the pleats. The ends of the support wrap are preferably spaced a short distance from the ends of the filter media such that the adhesive for the end caps can easily bond to the filter media in layers and the end caps can be securely bonded to the ends of the filter media. Otherwise, the support wrap extends along the 10 entire axial length of the filter media.
The filter element is designed to be manufactured using common manufacturing techniques. For example, the inner support wrap can be wound around a mandrel, with the side edges of the support wrap overlapping one another. Although not necessary, the overlapping side edges can be adhesively secured together. A mass of adhesive can then be applied across the outer surface of the support wrap, such as in one or more beads, or in a continuous layer across the entire outer surface of the support wrap. The adhesive is preferably a commercially-available adhesive, such as a two-part urethane or epoxy with a catalyst which is heat or air curable, or can be other conventional adhesives, such as a single component adhesive of heat curable urethane or epoxy. Appropriate adhesives are well known to those skilled in the art. The pleated filter media can then be disposed in surrounding relation to the support wrap in a cylindrical form. The side edges of the filter media can be secured to one another, such as by a band or strip of adhesive applied along the adjacent side edges, as is also well-known in the art. The inner support wrap allows the preassembled filter media to be easily removed from (slid off) the mandrel and retain its cylindrical form.
As illustrated in Figures 4 and 5, end caps 22 and 24 are then located on the opposite end of the filter media. The end caps are preferably formed from conventional end cap material, for example a thermoplastic such as injection-molded nylon, or other material which is combustible and/or biodegradable, and which can be readily incinerated or disposed of in a landfill. The end caps are adhered to the ends of the filter media using an appropriate adhesive or potting compound. End caps 22 and 24 preferably both include imperforate annular disks 68, 69, respectively, disposed against the ends of the filter media 20. An outer annular flange extends axially inward around the periphery of each end cap, partially along the outer surface of the filter media. Specifically, outer annular flange 70 on end cap 22 extends inwardly from disk 68, while outer annular flange 71 on end cap 24 extends inwardly from disk 69.
Each end cap also includes a central opening for receiving an element locator of the filter housing.
Specifically, end cap 22 includes central opening 72 receiving element locator 12, while end cap 24 includes central opening 73 receiving element locator 14. Of course, if only one element locator is present, then one of the end caps can be a continuous uninterrupted disk, with no central opening. In any case, each end cap preferably includes an inner annular flange portion 74, 75, respectively, surrounding the opening in the end cap. The annular flanges also extend axially inward partially along the inner surface of the filter media.
As indicated previously, the support wrap does not extend out entirely to the ends of the filter media, but rather terminates at an axial location spaced from the ends of the filter media and also from the inner annular flange of the end cap. The spacing of the support wrap from the ends of the filter media allows the end caps to be easily located on the ends of the filter media and the adhesive to securely attach the end caps to the layers of the media. The inner annular flanges on the end caps preferably have about the same radial thickness (.769 mm (.030 inches)) as the support wrap, such that a substantially flush and continuous inner surface on the filter media is provided.
Each inner flange 74, 75 on the end caps also has a radially-inward facing groove which receives an elastomeric O-ring 80, 82, respectively. Each O-ring seals against the element locator for the housing to provide a fluid-tight seal between the filter element and the filter housing at both ends of the filter element. While the element locators can of course have different configurations . o .._,.,1~-, .,y.-r'Y
r ~.;~LI
depending upon the particular application, the element locator 12 illustrated in Figure 4 has a cylindrical sleeve or collar 84 with an outer smooth surface which is sealed by O-ring 80 of end cap 22. Element locator 12 also includes an outwardly-projecting shoulder 86 with a flat inner surface 88 which can abut the outer surface 90 of flange 72, however, O-ring 80 allows flange 72 to be located along sleeve 84 at any axial location, and still maintain a proper seal between the filter element and the end cap.
At the opposite end of the filter element illustrated in Figure 5, element locator 14 preferably has substantially the same structure as the element locator 12, that is, a cylindrical sleeve or collar 94 with a smooth exterior surface and an outwardly projecting shoulder 96.
However, instead of O-ring seal 82 being sealed directly to collar 94, O-ring seal 82 can be sealed to the outer surface of the cylindrical inner support core 18. Specifically, inner support core 18 has an outer annular flange 100 preferably formed of the same material as the support core (metal) and secured at one end thereto such as by welding. The inner support core 18 can received around the annular flange and located within an annular channel formed at the inner end 102 of the flange. The annular channel provides that the exterior surface of flange 100 is substantially flush with the exterior surface of core 18. Flange 100 in turn is attached in sealed relation to element locator 14. Specifically, flange 100 can have an inner annular groove which receives an elastomeric O-ring 106. O-ring 106 seals against the outer surface of collar 94 on element locator 14. Flange 100 can be secured to element locator 14 such as by the compressive force of O-ring 106, or by other means which allows the support core to be removed from the element locator.
Of course, inner support core 18 can also be formed in one piece or otherwise permanently secured to element locator 14 if the application so dictates, however, the removable end flange 100 on the support core allows the coreless filter element to be retrofitted to existing filter housing designs, and also to be easily removed and inspected, if necessary.
As indicated above, the support tube is preferably comprised of metal and is formed in a cylinder by bringing opposite side edges of a sheet of perforated metal together and securing the edges together by, e.g., welding. A second annular flange 108 is preferably formed of the same material as the support core (metal) and secured to the other end of the core such as by e.g., welding. The support core 18 can also be received in an inner annular groove on the second annular flange such that the outer surface of the support core is substantially flush with the second annular flange. First annular flange 100 and second annular flange 108 provide smooth distal ends for the support core so as not to catch or tear the support wrap.
However, smooth ends could also be provided using other techniques such as coining or crimping the ends of the support core over to form rolled edges.
To assemble filter element 20 in the filter housing, the inner support core 18 is initially secured to element locator 14. Next, filter element 20 is disposed over the support core 18, with end cap 24 being first received over the support core, and inserted over the support core until O-ring 82 seals against flange 100. Filter element 20 slides smoothly and cleanly over the inner support core by virtue of the smooth interior surface of support wrap 64, with the support wrap acting as a spacer to allow end cap 24 to slide easily past the support core.
Preferably, when assembled, support wrap 64 is in adjacent, closely surrounding relation with inner support core 18 such that the inner support core provides longitudinal and radial support for filter media 20. In addition, support wrap 64 prevents the pleated media from directly contacting the inner support core, and catching or binding along the support core as the filter element is inserted. Finally, the opposite element locator 12 is attached to the filter element, with the O-ring seal 80 on end cap 22 sealing against element locator 12. Although not shown, element locator 12 can be incorporated into a removable end cap of the filter housing.
In removing a spent or used filter element from the housing, the above process is reversed, that is, element locator 12 is detached from the filter element, and the filter element is slid off the inner support core 18. Again, the filter element can be removed in a smooth and easy manner because of the support wrap 64 sliding easily against the inner support core 18.
E;CV.W v:E.E~.A-W E:~C'tiE~, W~ . :3- !>-;7r3 ~A 02247957 1998-08-28~r39Ei~1n:°r-. +43 ~3:n '?39:1-~4E3:p:#1~'~
1~
According to another embodiment of the present invention, as illustrated in Figure b:
the supporting sheet for the filter element 10 can alternatively inc.fude one or more support bands extending cireumferentially around the inner surface of the filter media in the cylindri;.al cavity 58_ For ezample, Figure 6 illustrates three separate annular support bands 120, 1~2 and 12g disposed in spaced-apart relation around the inner surface of the filter media. Support band 120 ran be located close to anc end of the filter media (proximate end cap 22), support band 124 can be located close to another end of :he fiber media (proximat~ end cap ~) and support bararl 122 can be located between support band 120 and support baud 124 at approximately the center point along the filter m.:dia. Preferably the outer two support bands LC 12~r and 12.4 a:e spac;.d apan i'rom the end caps of the filter media such that fluid flow through the fil;~r media is allo~aved betweatt the outer support bands and the end caps. This also allows h;, end caps to be securely adhesively fixed to the endc of the fiber mr:dia, as prwiousIy describ.°,d ~'h~ support bars3s are prrferably formed from an imperforate thermoplastic material 1 a such as nylon, or can be corttprised of a fibrous filter material such as described previously ~x~ich respect to the support v~rap. Again, it is preferred that the material is combustible or c~ic~degradable so as to be easily disposed of in a landfill. Also, ~'te support bands preferably hav a the sam: thickness as the support wrap described previously (.769mm (.03U inches)), anf are jeirted to the it'sr<er peal. pleats c~f the filter media such as by depositing a head or tayzr of 2n adhesive along the aut;.r surface of the hands.
As with the support wrap, the support bands provide structz:ral integrity for thr pleats on the fiber element, and more specifically, prevent tfsa pleats fxora moNing relative :o one another sacb that the filter element retaists its cylizuixical form. T'he support hands also allow the fJt~r element to be easily Located over the inner support core IS as the bands have a smooth 25 inner surfacz which is easily slid over the care, and prevent the picots zrom directl;~ contgcting the core. Ti he bandy also act as spacers to allow the etu: cap 2~ w slide pas3 the support core when ius~rting the ftltcr elerlent over the core. The nurnber, spacing and width of the support bands ,:ors be chosen depending upon the particular application, and can be determined by simple experimenta-tion.
The filter element can be assembled in much the same manner as described previously, with the support bands being disposed around the mandrel and a layer of adhesive applied to the 5 outer surface of the support bands, with the pleated or corrugated filter media then disposed in a cylinder form around the bands. While the support bands are disclosed as extending annularly around the inside surface of the filter media, it is also within the scope of present invention to provide one or mare support bands in a spiral or helical fashion circumferentially around the inside surface of the filter media, as along as the support bands) provide sufficient strength and integrity 10 for the filter element.
In either of the embodiments described above, the present invention provides a novel and unique coreless filter element which can be easily located over a support core integral with a filter housing, and removed from the support core and replaced when necessary.
According to either of the embodiments described above, the support wrap or bands) provide integrity and strength 15 for the pleated filter media without requiring an outer wrap surrounding the filter element, and can be easily manufactured using common techniques. Finally, the filter element of the present invention is particularly designed with incineratable or biodegradable components which can be disposed of in a commercial landfill.
Immediately adjacent the inner surface of the capacity layer 31 is a microfiber filtration layer 36. The microfiber filtration layer is preferably comprised of the same material as the prefiltration layer, for example borosilicate microglass fibers with acrylic binder, but with a finer fiber or tighter structure than the prefiltration layer. Generally, the microfiber filtration layer defines the filtration efficiency of the filter element, and is generally about ten times the filtration efficiency of the prefiltration layer.
Immediately adjacent the inner surface of the filtration layer 36 is an inner support mesh layer 38. The inner support mesh layer 38 also preferably comprises the same material as in the outer support mesh layer 30, such as a thermoplastic synthetic resinous material which can be woven or extruded.
The thickness and porosity of the layers described above can vary depending upon the particular filtering application, and can be determined using simple experimentation. Further, as should be apparent to those skilled in the art, the preferred filter media structure described above is a combustible or biodegradable structure such that the filter media can be relatively easily disposed of in a commercial landfill. However, while the filter media structure 20 is preferably formed in the mufti-layered structure described above, it should be apparent to those of ordinary skill in the art that the filter media structure can have other known single or mufti-layered structures.
CA 02247957 1998-08-28,;f;~)f>4 W'.~ ~-~;) t~:~ _':;9'u-Et;;~: ~' r yt . t o'~.: t~f'a-t11 L:'(.'lIU\ u_~ . :3- E~-:)>3 . ,..~. z~ . _ _ in any case, rate filter media 2~ s preferab:y plated, that is, chc filter media includes axially-extending pleats ~xt<:n3ing from end cap 22 to end cap 24. Ea;,h pleat has a raciialiy outer pleat peak (ope:n end), sucJu as inriicat~ at 50, and a rsdi311y inner pleat peak (closed end), such zs indicated at ~2. Fach pleat atso includes sld~r~~alls, such as i1I115CraCed at >4 and 5~, which together with the outer pleat peaks SO arid inner pleat peaks ~~
define a series of radialty-outward opening pl=zt caviti;.s around the cirLsfnference of the filter element. 'phe cylindrical phated filter media also denn~s a cylindrical cavity, indicated genera.!ly a: ~R in Figure 1, centrally within the filter element. T'he techniques for piea:i;~ or corrugating the filter media are conve:ztioz~al in nature, and can include hand-forming or forming using a pleat machine.
To provide rigidity and structut~al ir_tegrity for the pleated filler media; a supporting sheet comprising an inner support wrap, it>dlcated xt b4 in Figures ? and 3, is dapc;sed wahin the cylindrical cavity of the filter element, Inner support wrap 64 prefera~yly comprises a porous, fibrous filter media of a non-woven thermoplastic syntheti:. rrsin, such as polyestEr.
The inner support wrap is preferably a :~p~un-boruied traterial. A "spun-bo:rde~" maceriai oan be prepared by depositing extruded thermoplastic synthetic resin filaments into a non-~NOVen mat while the filaments are in a soft or partially molten fot7n. The soft fibers generally th~rmalJy adh'rre to one ay~ather, i.e., mel: bond, and when ceateci, force an integra.i mass of non-woven fil3tnentary struc:ure. The iz~rter-support wrap can also be formed from spun-z~ bonded glass fibers, dltbough polyester fibers are preferred. Support wrap fr4 preferably has a permeability of at least tea times the perme~it:ty of the filte: media 10, and does not appreciably affect the pressure drop across the .filter element. As should be apparent from the above, the support wrap is also preferably formed from a combustible or ittci:neratnhle rnater:al, similar to the material forming the filter cn~dia, such that the composite, stnictura car. be z5 relatively easily incinerated or disposed of in a commercial landfill.
The support wrap 54 is formed in a cylindrical or tubutar fornr., with the outer surface of the suppor! wrap being joined to the in:oer pleat peaks 52 of the pleats.
Preferably, the ,upport wrap 6.~ is joined to tire inner pIe3t peaks by conventional adhesive which oan be applied to the outer surface of the support wrap in one or more beads (circumferentially or helically applied), or alternatively, applied continuously in a coating or layer across the entire outer surface of the support wrap. A layer of adhesive is indicated at 65 in Figure 3. The adhesive bonds the inner pleat peaks to the support wrap, which fixes the inner pleat peaks with respect to one another and 5 provides rigidity and structural integrity for the pleated filter media. The support wrap is of course unattached and is spaced from the filter media at the locations between the pleats. The ends of the support wrap are preferably spaced a short distance from the ends of the filter media such that the adhesive for the end caps can easily bond to the filter media in layers and the end caps can be securely bonded to the ends of the filter media. Otherwise, the support wrap extends along the 10 entire axial length of the filter media.
The filter element is designed to be manufactured using common manufacturing techniques. For example, the inner support wrap can be wound around a mandrel, with the side edges of the support wrap overlapping one another. Although not necessary, the overlapping side edges can be adhesively secured together. A mass of adhesive can then be applied across the outer surface of the support wrap, such as in one or more beads, or in a continuous layer across the entire outer surface of the support wrap. The adhesive is preferably a commercially-available adhesive, such as a two-part urethane or epoxy with a catalyst which is heat or air curable, or can be other conventional adhesives, such as a single component adhesive of heat curable urethane or epoxy. Appropriate adhesives are well known to those skilled in the art. The pleated filter media can then be disposed in surrounding relation to the support wrap in a cylindrical form. The side edges of the filter media can be secured to one another, such as by a band or strip of adhesive applied along the adjacent side edges, as is also well-known in the art. The inner support wrap allows the preassembled filter media to be easily removed from (slid off) the mandrel and retain its cylindrical form.
As illustrated in Figures 4 and 5, end caps 22 and 24 are then located on the opposite end of the filter media. The end caps are preferably formed from conventional end cap material, for example a thermoplastic such as injection-molded nylon, or other material which is combustible and/or biodegradable, and which can be readily incinerated or disposed of in a landfill. The end caps are adhered to the ends of the filter media using an appropriate adhesive or potting compound. End caps 22 and 24 preferably both include imperforate annular disks 68, 69, respectively, disposed against the ends of the filter media 20. An outer annular flange extends axially inward around the periphery of each end cap, partially along the outer surface of the filter media. Specifically, outer annular flange 70 on end cap 22 extends inwardly from disk 68, while outer annular flange 71 on end cap 24 extends inwardly from disk 69.
Each end cap also includes a central opening for receiving an element locator of the filter housing.
Specifically, end cap 22 includes central opening 72 receiving element locator 12, while end cap 24 includes central opening 73 receiving element locator 14. Of course, if only one element locator is present, then one of the end caps can be a continuous uninterrupted disk, with no central opening. In any case, each end cap preferably includes an inner annular flange portion 74, 75, respectively, surrounding the opening in the end cap. The annular flanges also extend axially inward partially along the inner surface of the filter media.
As indicated previously, the support wrap does not extend out entirely to the ends of the filter media, but rather terminates at an axial location spaced from the ends of the filter media and also from the inner annular flange of the end cap. The spacing of the support wrap from the ends of the filter media allows the end caps to be easily located on the ends of the filter media and the adhesive to securely attach the end caps to the layers of the media. The inner annular flanges on the end caps preferably have about the same radial thickness (.769 mm (.030 inches)) as the support wrap, such that a substantially flush and continuous inner surface on the filter media is provided.
Each inner flange 74, 75 on the end caps also has a radially-inward facing groove which receives an elastomeric O-ring 80, 82, respectively. Each O-ring seals against the element locator for the housing to provide a fluid-tight seal between the filter element and the filter housing at both ends of the filter element. While the element locators can of course have different configurations . o .._,.,1~-, .,y.-r'Y
r ~.;~LI
depending upon the particular application, the element locator 12 illustrated in Figure 4 has a cylindrical sleeve or collar 84 with an outer smooth surface which is sealed by O-ring 80 of end cap 22. Element locator 12 also includes an outwardly-projecting shoulder 86 with a flat inner surface 88 which can abut the outer surface 90 of flange 72, however, O-ring 80 allows flange 72 to be located along sleeve 84 at any axial location, and still maintain a proper seal between the filter element and the end cap.
At the opposite end of the filter element illustrated in Figure 5, element locator 14 preferably has substantially the same structure as the element locator 12, that is, a cylindrical sleeve or collar 94 with a smooth exterior surface and an outwardly projecting shoulder 96.
However, instead of O-ring seal 82 being sealed directly to collar 94, O-ring seal 82 can be sealed to the outer surface of the cylindrical inner support core 18. Specifically, inner support core 18 has an outer annular flange 100 preferably formed of the same material as the support core (metal) and secured at one end thereto such as by welding. The inner support core 18 can received around the annular flange and located within an annular channel formed at the inner end 102 of the flange. The annular channel provides that the exterior surface of flange 100 is substantially flush with the exterior surface of core 18. Flange 100 in turn is attached in sealed relation to element locator 14. Specifically, flange 100 can have an inner annular groove which receives an elastomeric O-ring 106. O-ring 106 seals against the outer surface of collar 94 on element locator 14. Flange 100 can be secured to element locator 14 such as by the compressive force of O-ring 106, or by other means which allows the support core to be removed from the element locator.
Of course, inner support core 18 can also be formed in one piece or otherwise permanently secured to element locator 14 if the application so dictates, however, the removable end flange 100 on the support core allows the coreless filter element to be retrofitted to existing filter housing designs, and also to be easily removed and inspected, if necessary.
As indicated above, the support tube is preferably comprised of metal and is formed in a cylinder by bringing opposite side edges of a sheet of perforated metal together and securing the edges together by, e.g., welding. A second annular flange 108 is preferably formed of the same material as the support core (metal) and secured to the other end of the core such as by e.g., welding. The support core 18 can also be received in an inner annular groove on the second annular flange such that the outer surface of the support core is substantially flush with the second annular flange. First annular flange 100 and second annular flange 108 provide smooth distal ends for the support core so as not to catch or tear the support wrap.
However, smooth ends could also be provided using other techniques such as coining or crimping the ends of the support core over to form rolled edges.
To assemble filter element 20 in the filter housing, the inner support core 18 is initially secured to element locator 14. Next, filter element 20 is disposed over the support core 18, with end cap 24 being first received over the support core, and inserted over the support core until O-ring 82 seals against flange 100. Filter element 20 slides smoothly and cleanly over the inner support core by virtue of the smooth interior surface of support wrap 64, with the support wrap acting as a spacer to allow end cap 24 to slide easily past the support core.
Preferably, when assembled, support wrap 64 is in adjacent, closely surrounding relation with inner support core 18 such that the inner support core provides longitudinal and radial support for filter media 20. In addition, support wrap 64 prevents the pleated media from directly contacting the inner support core, and catching or binding along the support core as the filter element is inserted. Finally, the opposite element locator 12 is attached to the filter element, with the O-ring seal 80 on end cap 22 sealing against element locator 12. Although not shown, element locator 12 can be incorporated into a removable end cap of the filter housing.
In removing a spent or used filter element from the housing, the above process is reversed, that is, element locator 12 is detached from the filter element, and the filter element is slid off the inner support core 18. Again, the filter element can be removed in a smooth and easy manner because of the support wrap 64 sliding easily against the inner support core 18.
E;CV.W v:E.E~.A-W E:~C'tiE~, W~ . :3- !>-;7r3 ~A 02247957 1998-08-28~r39Ei~1n:°r-. +43 ~3:n '?39:1-~4E3:p:#1~'~
1~
According to another embodiment of the present invention, as illustrated in Figure b:
the supporting sheet for the filter element 10 can alternatively inc.fude one or more support bands extending cireumferentially around the inner surface of the filter media in the cylindri;.al cavity 58_ For ezample, Figure 6 illustrates three separate annular support bands 120, 1~2 and 12g disposed in spaced-apart relation around the inner surface of the filter media. Support band 120 ran be located close to anc end of the filter media (proximate end cap 22), support band 124 can be located close to another end of :he fiber media (proximat~ end cap ~) and support bararl 122 can be located between support band 120 and support baud 124 at approximately the center point along the filter m.:dia. Preferably the outer two support bands LC 12~r and 12.4 a:e spac;.d apan i'rom the end caps of the filter media such that fluid flow through the fil;~r media is allo~aved betweatt the outer support bands and the end caps. This also allows h;, end caps to be securely adhesively fixed to the endc of the fiber mr:dia, as prwiousIy describ.°,d ~'h~ support bars3s are prrferably formed from an imperforate thermoplastic material 1 a such as nylon, or can be corttprised of a fibrous filter material such as described previously ~x~ich respect to the support v~rap. Again, it is preferred that the material is combustible or c~ic~degradable so as to be easily disposed of in a landfill. Also, ~'te support bands preferably hav a the sam: thickness as the support wrap described previously (.769mm (.03U inches)), anf are jeirted to the it'sr<er peal. pleats c~f the filter media such as by depositing a head or tayzr of 2n adhesive along the aut;.r surface of the hands.
As with the support wrap, the support bands provide structz:ral integrity for thr pleats on the fiber element, and more specifically, prevent tfsa pleats fxora moNing relative :o one another sacb that the filter element retaists its cylizuixical form. T'he support hands also allow the fJt~r element to be easily Located over the inner support core IS as the bands have a smooth 25 inner surfacz which is easily slid over the care, and prevent the picots zrom directl;~ contgcting the core. Ti he bandy also act as spacers to allow the etu: cap 2~ w slide pas3 the support core when ius~rting the ftltcr elerlent over the core. The nurnber, spacing and width of the support bands ,:ors be chosen depending upon the particular application, and can be determined by simple experimenta-tion.
The filter element can be assembled in much the same manner as described previously, with the support bands being disposed around the mandrel and a layer of adhesive applied to the 5 outer surface of the support bands, with the pleated or corrugated filter media then disposed in a cylinder form around the bands. While the support bands are disclosed as extending annularly around the inside surface of the filter media, it is also within the scope of present invention to provide one or mare support bands in a spiral or helical fashion circumferentially around the inside surface of the filter media, as along as the support bands) provide sufficient strength and integrity 10 for the filter element.
In either of the embodiments described above, the present invention provides a novel and unique coreless filter element which can be easily located over a support core integral with a filter housing, and removed from the support core and replaced when necessary.
According to either of the embodiments described above, the support wrap or bands) provide integrity and strength 15 for the pleated filter media without requiring an outer wrap surrounding the filter element, and can be easily manufactured using common techniques. Finally, the filter element of the present invention is particularly designed with incineratable or biodegradable components which can be disposed of in a commercial landfill.
Claims (6)
1. A replaceable filter element removably disposed about a permanent rigid support core, said filter element having cylindrical filter media with pleats extending in the axial direction of the cylinder filter media from one end of the filter media to another end of the filter media, said pleats having radially-inner pleat peaks, radially outer pleat peaks, and opposing sidewalls extending between respective inner pleat peaks and outer pleat peaks which define outwardly-opening pleat cavities around the filter element, a radially-inner surface of the inner pleat peaks defining a central, longitudinally-extending cylindrical cavity within the filter media, characterized in that a flexible cylindrical support means formed from a wrap of porous, fibrous filter media of a non-woven thermoplastic synthetic resin is disposed within the central cavity of the cylindrical filter media supporting the inner pleat peaks and allowing fluid to flow between the media and the support core, said support means having a radially outer surface bonded by a mass of adhesive directly to the radially-inner surface of the inner pleat peaks, and a radially inner surface freely disposed against said support core, such that the filter element can be easily located over the support core and removed from the support core when spent without damage to the pleats; and an imperforate end cap bonded to each end of said filter media, one end cap including an annular disk with a central opening for receiving the support core, said central opening having an inner diameter that is substantially equal to an inner diameter of the support means.
2. The filter element as in claim 1, wherein the support means comprises a plurality of individual cylindrical support bands spaced apart along the longitudinal extent of the filter media, each of said bands comprising a strip of material bonded by a mass of adhesive directly to the radially inner surface of the inner pleat peaks.
3. The filter element as in claims 1 or 2, further comprising a radially-inward facing groove around the central opening to the one end cap, and a resilient O-ring seal disposed within the groove, and projecting radially-inward into the opening for sealing against the support core.
4. The filter element as in any one of claims 1 - 3, wherein said filter media includes a multi-layered structure having i) an outer layer of a support mesh, ii) an adhesive web layer disposed adjacent a radially inner surface of the support mesh, iii) a microfiber capacity layer disposed adjacent a radially inner surface of the adhesive web layer, iv) a microfiber filtration layer disposed adjacent a radially inner surface of the capacity layer, and v) an inner layer of a support mesh disposed adjacent a radially inner surface of the filtration layer.
5. The filter element as in any one of claims 1 - 4, wherein the outer pleat peaks are self-supporting and are without an outer wrap interconnecting the pleat peaks.
6. A filter assembly for the filter element of claim 1, wherein the assembly comprises a first fluid conduit at a first end of a housing and a second fluid conduit at another end of the housing, opposite from the first end, to direct fluid into or out of the assembly, and the support core has a cylindrical, perforated shape, and is connected to the second fluid conduit and extends toward the first fluid conduit.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US1358096P | 1996-03-01 | 1996-03-01 | |
| US60/013,580 | 1996-03-01 | ||
| PCT/US1997/002308 WO1997031695A1 (en) | 1996-03-01 | 1997-02-20 | Coreless non-metallic filter element |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2247957A1 CA2247957A1 (en) | 1997-09-04 |
| CA2247957C true CA2247957C (en) | 2006-06-06 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002247957A Expired - Lifetime CA2247957C (en) | 1996-03-01 | 1997-02-20 | Coreless non-metallic filter element |
Country Status (9)
| Country | Link |
|---|---|
| US (1) | US6099729A (en) |
| EP (1) | EP0883429B1 (en) |
| AT (1) | ATE337059T1 (en) |
| BR (1) | BR9707730A (en) |
| CA (1) | CA2247957C (en) |
| DE (1) | DE69736548T2 (en) |
| DK (1) | DK0883429T3 (en) |
| ES (1) | ES2268725T3 (en) |
| WO (1) | WO1997031695A1 (en) |
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-
1997
- 1997-01-31 US US08/792,036 patent/US6099729A/en not_active Expired - Lifetime
- 1997-02-20 DK DK97907625T patent/DK0883429T3/en active
- 1997-02-20 WO PCT/US1997/002308 patent/WO1997031695A1/en active IP Right Grant
- 1997-02-20 ES ES97907625T patent/ES2268725T3/en not_active Expired - Lifetime
- 1997-02-20 AT AT97907625T patent/ATE337059T1/en not_active IP Right Cessation
- 1997-02-20 CA CA002247957A patent/CA2247957C/en not_active Expired - Lifetime
- 1997-02-20 BR BR9707730A patent/BR9707730A/en not_active IP Right Cessation
- 1997-02-20 DE DE69736548T patent/DE69736548T2/en not_active Expired - Lifetime
- 1997-02-20 EP EP97907625A patent/EP0883429B1/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| EP0883429A1 (en) | 1998-12-16 |
| CA2247957A1 (en) | 1997-09-04 |
| WO1997031695A1 (en) | 1997-09-04 |
| EP0883429B1 (en) | 2006-08-23 |
| ES2268725T3 (en) | 2007-03-16 |
| US6099729A (en) | 2000-08-08 |
| BR9707730A (en) | 1999-07-27 |
| DK0883429T3 (en) | 2006-12-11 |
| ATE337059T1 (en) | 2006-09-15 |
| DE69736548T2 (en) | 2007-09-13 |
| DE69736548D1 (en) | 2006-10-05 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKEX | Expiry |
Effective date: 20170220 |