US-12616928-B2 - Filter element with improved dust loading

Abstract

Embodiments disclosed herein relate to a pleated filter element having filter media having a downstream layer of filter material and an upstream layer of fibers. A spacing structure defines a void space between the upstream layer of fibers and the downstream layer of filter material.

Inventors

• Gregory S. Tronnes
• Robert M. Rogers
• Aflal Rahmathullah

Assignees

• DONALDSON COMPANY, INC.

Dates

Publication Date

20260505

Application Date

20210927

Claims (20)

1. 1 . A filter element comprising: filter media in a pleated configuration having a first set of pleat folds forming an upstream face and a second set of pleat folds forming a downstream face, the filter media having a perimeter region, the filter media comprising: a downstream layer of filter material in a corrugated configuration defining peaks and valleys; and an upstream layer of fibers extending across the peaks of the downstream layer of filter material, wherein a void space is defined between the downstream layer of filter material and the upstream layer of fibers, and the upstream layer of fibers has less than 10% solidity; and a frame component secured to the perimeter region of the filter media.
2. 2 . The filter element of claim 1 , wherein the downstream layer of filter material has a capture efficiency of at least 10%.
3. 3 . The filter element of claim 1 , wherein the upstream layer of fibers is not self-supporting.
4. 4 . The filter element of claim 1 , wherein the downstream layer of filter material defines corrugations having a mean corrugation depth of greater than 0.23 mm.
5. 5 . The filter element of claim 1 , wherein the downstream layer of filter material is self-supporting.
6. 6 . A method of constructing a filter element, the method comprising: creating a spacing structure on a layer of filter material; depositing a layer of fibers across the spacing structure of the filter material to form filter media, wherein a void space is defined between the filter material and the layer of fibers; pleating the filter media to define a first set of pleat folds and a second set of pleat folds, wherein the first set of pleat folds form an upstream face and the second set of pleat folds form a downstream face; and securing a perimeter region of the filter media to a frame component.
7. 7 . The method of claim 6 , wherein the layer of filter material has a capture efficiency of at least 10%.
8. 8 . The method of claim 6 , wherein creating the spacing structure comprises forming corrugations in the layer of filter material.
9. 9 . The method of claim 6 , wherein the layer of filter material is corrugated to have a mean corrugation depth of greater than 0.23 mm.
10. 10 . The method of claim 6 , wherein creating the spacing structure comprises depositing a spacing structure on an upstream surface of the layer of filter material.
11. 11 . A filter element comprising: filter media in a pleated configuration having a first set of pleat folds forming an upstream face and a second set of pleat folds forming a downstream face, the filter media having a perimeter region, the filter media comprising: a downstream layer of filter material, wherein the downstream layer of filter material has a capture efficiency of at least 10%; and an upstream layer of fibers, wherein the upstream layer of fibers has a solidity of less than 10%; and a spacing structure defining a mean void distance between the upstream layer of fibers and the downstream layer of filter material greater than 0.11 mm; and a frame component secured to the perimeter region of the filter media.
12. 12 . The filter element of claim 1 , wherein the spacing structure comprises protrusions from the downstream layer of filter material in a direction perpendicular to a length and a width of the filter media.
13. 13 . The filter element of claim 11 , wherein the spacing structure includes corrugations defined by the downstream layer of filter material.
14. 14 . The filter element of claim 11 , wherein the spacing structure includes embossments defined by the downstream layer of filter material.
15. 15 . The filter element of claim 11 , wherein the spacing structure includes deposits disposed between the upstream layer of fibers and the downstream layer of filter material.
16. 16 . The filter element of claim 11 , wherein the upstream layer of fibers is not self-supporting.
17. 17 . The filter element of claim 11 , wherein the upstream layer of fibers is non-corrugated.
18. 18 . The filter element of claim 11 , wherein the downstream layer of filter material is non-corrugated.
19. 19 . The filter element of claim 11 , wherein the downstream layer of filter material is self-supporting.
20. 20 . The filter media of claim 11 , wherein the mean void distance between the upstream layer of fibers and the downstream layer of filter material is less than 1.0 mm.

Description

CROSS REFERENCE TO RELATED APPLICATIONS This application is the § 371 U.S. National Stage of International Application No. PCT/US2021/052198, filed 27 Sep. 2021, which claims the benefit of U.S. Provisional Application No. 63/084,516, filed 28 Sep. 2020, the disclosures of which are incorporated by reference herein in their entireties. TECHNOLOGICAL FIELD The technology disclosed herein generally relates to filter elements. More particularly, the technology disclosed herein relates to filter elements with improved dust loading. BACKGROUND The life of the filter element is limited, at least in part, by the collection of dust and other particulates by the filter media within the filter element. As the volume and mass of the particulates on the upstream face and inside the filter media builds up, the filter media become increasingly resistant to receiving fluid flow. The resistance of airflow through the filter media is reflected by a differential pressure measurement between the upstream side and the downstream side of the filter media if the flow rate is constant, or a reduction in airflow rate if the differential pressure is constant. An increasing differential pressure measurement is indicative of increasing resistance to fluid flow, and a relatively high differential pressure measurement is indicative of the end of the service life of the filter media. SUMMARY The technology disclosed herein relates to a filter element that exhibits improved dust loading. The improved dust loading can extend the useful life of the filter element. Some embodiments relate to a filter element having filter media in a pleated configuration having a first set of pleat folds and a second set of pleat folds. The first set of pleat folds form an upstream face. The second set of pleat folds form a downstream face. The filter media has a perimeter region. The filter media has a downstream layer of filter material and an upstream layer of fibers. The downstream layer of filter material is in a corrugated configuration defining peaks and valleys. The upstream layer of fibers extends across the peaks of the downstream layer of filter material. A void space is defined between the downstream layer of filter material and the upstream layer of fibers. The upstream layer of fibers has less than 10% solidity. A frame component is secured to the perimeter region of the filter media. In some such embodiments a plurality of fibers in the upstream layer of fibers are crimped. Additionally or alternatively, the upstream layer of fibers has a mean fiber diameter of at least 10 microns. Additionally or alternatively, the downstream layer of filter material has a capture efficiency from 20% to 40%. Additionally or alternatively, the downstream layer of filter material comprises cellulose fibers. Additionally or alternatively, the cellulose fibers comprise wet-laid cellulose fibers. Additionally or alternatively, the downstream layer of filter material comprises synthetic fibers. Additionally or alternatively, the upstream layer of fibers comprises polymeric fibers. Additionally or alternatively, the downstream layer of filter material comprises fibers having a mean fiber diameter from 4 to 30 microns. Additionally or alternatively, the upstream layer of fibers is not self-supporting. Additionally or alternatively, the upstream layer of fibers is an upstream-most layer, and the upstream layer of fibers is in direct contact with the downstream layer of filter material. Additionally or alternatively, the downstream layer of filter material has a capture efficiency of at least 10%. Additionally or alternatively, the downstream layer of filter material has a mean corrugation depth of less than 2.0 mm. Additionally or alternatively, the downstream layer of filter material defines corrugations having a mean corrugation depth of greater than 0.23 mm. Additionally or alternatively, the upstream layer of fibers is non-corrugated. Additionally or alternatively, the downstream layer of filter material is self-supporting. Additionally or alternatively, a mean void distance is defined between the downstream layer of filter media and the upstream layer of fibers. Additionally or alternatively, the pleat density of the pleats is from 1 pleat per inch to 14 pleats per inch. Additionally or alternatively, there are at least 5 corrugation peaks per pleat. Additionally or alternatively, there are 15 to 200 corrugation peaks per pleat. Additionally or alternatively, the pleats are perpendicular to the corrugation peaks. Some embodiments of the technology disclosed herein are directed to a method of constructing a filter media. A spacing structure is created on a layer of filter material. A layer of fibers is deposited across the spacing structure of the filter material to form filter media. A void space is defined between the downstream layer of filter material and the layer of fibers. The filter media is pleated to define a first set of pleat folds and a second set of