Multi-layer pleat support filter construction

• US 20040060858A1
• Filed: 09/24/2003
• Published: 04/01/2004
• Est. Priority Date: 09/26/2002
• Status: Abandoned Application

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Morby, John, Lucas, Jeffrey A., Paul, C. Thomas
• Application Number:
  US10/669,533
• Publication Number:
  US 20040060858A1
• Time in Patent Office: Days
• US Class Current: 210/338
• CPC Class Codes: B01D 2201/0407 Perforated supports on both sides of the filtering element
• CPC Class Codes: B01D 2201/188 Multiple filtering elements having filtering areas of different size
• CPC Class Codes: B01D 29/21 with corrugated, folded or wound sheets
• CPC Class Codes: B01D 63/067 with pleated membranes

Abstract

A filter element is disclosed that includes a filtration media, an upstream pleat support and a multi-layer downstream pleat support. The multi-layer downstream support includes a first downstream support layer and a second downstream support layer. The first downstream support layer is in contact with the filtration media and is interposed between the filtration media and the second downstream layer. The first downstream support layer is fabricated so as to minimize points of surface contact with the filtration media, thereby enhancing fluid flow away from the filtration media. The second downstream support layer is in contact with the first downstream support layer and is fabricated so as to facilitate lateral fluid flow relative to the multi-layer downstream pleat support. The disclosed filter element may be utilized in filter cartridges of various designs to provide enhanced filtration performance, e.g., by way of increased media area and improved flow/throughput.

Claims

1. A filter element, comprising:

a filtration media;

an upstream filtration media support positioned upstream from and in contact with said filtration media; and

a multi-layer downstream filtration media support positioned downstream from said filtration media, said multi-layer downstream support including a first downstream support layer and a second downstream support layer, wherein;

(a) said first downstream support layer is in contact with said filtration media and is interposed between said filtration media and said second downstream layer, said first downstream support layer is fabricated so as to minimize points of surface contact with said filtration media; and

(b) said second downstream support layer is in contact with said first downstream support layer and is fabricated so as to facilitate lateral fluid flow relative to said multi-layer downstream pleat support.

2. A filter element as recited in claim 1, wherein the filtration media is a pleated filtration media having a plurality of longitudinally extending pleats.

3. A filter element as recited in claim 2, wherein the longitudinally extending pleats of said pleated filtration media are selected from the group consisting of radial pleats, w-pleats and spiral pleats.

4. A filter element as recited in claim 1, wherein the filtration media is a microporous filtration membrane having a pore size of from about 0.1 microns to about 10 microns.

5. A filter element as recited in claim 1, wherein the filtration media is fabricated from a material selected from the group consisting of Teflon, nylon, polyaramide, polyvinylidene difluoride, polyether sulfone and combinations thereof.

6. A filter element as recited in claim 1, wherein the multi-layer downstream support consists of said first downstream support layer and said second downstream support layer.

7. A filter element as recited in claim 1, wherein said first downstream support layer is fabricated from a nonwoven material.

8. A filter element as recited in claim 7, wherein said nonwoven material is laminated to said filtration media.

9. A filter element as recited in claim 7, wherein said nonwoven material is fabricated as a spunbond, spunlace, airlaid or wetlaid material.

10. A filter element as recited in claim 7, wherein said nonwoven material is fabricated from polypropylene, polyester or polyamide.

11. A filter as recited in claim 1, wherein said second downstream support layer is an extruded apertured element.

18. A filter element as recited in claim 1, wherein said second downstream support layer is an extruded apertured element.

19. A filter element as recited in claim 1, wherein said second downstream support layer is an extruded apertured element having ribs formed on one side.

12. A filter element, comprising:

a filtration media;

an upstream pleat support positioned upstream from and in contact with said filtration media; and

a multi-layer downstream pleat support positioned downstream from said filtration media, said multi-layer downstream support including a first downstream support layer and a second downstream support layer, wherein;

(a) said first downstream support layer is in contact with said filtration media and is interposed between said filtration media and said second downstream layer, said first downstream support layer is fabricated so as to minimize points of surface contact with said filtration media; and

(b) said second downstream support layer is in contact with said first downstream support layer and is fabricated so as to facilitate lateral fluid flow relative to said multi-layer downstream pleat support.

13. A filter cartridge comprising:

a filter element having a longitudinal axis, an outer periphery and an inner periphery, and including a filtration media;

an upstream filter media support positioned upstream from and in contact with said filtration media; and

a multi-layer downstream support positioned downstream from said filtration media, said multi-layer downstream support including a first downstream support layer and a second downstream support layer, wherein;

(a) the first downstream support layer is in contact with said filtration media and is interposed between said filtration media and said second downstream layer, said first downstream support layer being fabricated so as to minimize points of surface contact with said filtration media; and

(b) the second downstream support layer is in contact with said first downstream support layer and is fabricated so as to facilitate lateral fluid flow relative to said multi-layer downstream filter media support;

a perforated cage surrounding the outer periphery of the filter element;

a perforated core surrounded by the inner periphery of the filter element; and

end caps enclosing both ends of the perforated cage.

14. A filter cartridge as recited in claim 13, wherein said first downstream support layer is fabricated from a nonwoven material.

15. A filter cartridge as recited in claim 14, wherein said nonwoven material is laminated to said filtration media.

16. A filter element as recited in claim 14, wherein said nonwoven material is fabricated as a spunbond, spunlace, airlaid or wetlaid material.

17. A filter element as recited in claim 14, wherein said nonwoven material is fabricated from polypropylene, polyester or polyamide.

20. A filter cartridge as recited in claim 13 wherein the perforated cage is equipped with end caps at both ends thereof.

21. A filter cartridge as recited in claim 13 wherein said perforated core is a cylindrical core and is coaxially positioned within the filter element which is a cylindrical filter element and the cage is likewise cylindrical and is coaxially positioned about the cylindrical filter element.

22. A filter cartridge comprising:

a filter element having a longitudinal axis, an outer periphery and an inner periphery, and including a filtration media; and

a multi-layer downstream pleat support positioned downstream from said filtration media, said multi-layer downstream support including a first downstream support layer and a second downstream support layer, wherein;

(a) the first downstream support layer is in contact with said filtration media and is interposed between said filtration media and said second downstream layer, said first downstream support layer being fabricated so as to minimize points of surface contact with said filtration media; and

(b) the second downstream support layer is in contact with said first downstream support layer and is fabricated so as to facilitate lateral fluid flow relative to said multi-layer downstream pleat support;

a perforated cage surrounding the outer periphery of the filter element;

a perforated core surrounded by the inner periphery of the filter element; and

end caps enclosing both ends of the perforated cage.