Box-V filter and method of fabricating the same

• US 20070204579A1
• Filed: 03/01/2006
• Published: 09/06/2007
• Est. Priority Date: 03/01/2006
• Status: Active Grant

• Current Assignee: Camfil AB
• Original Assignee: Camfil AB
• Inventors: Sundvik, Anders, Karlsson, Lennart, Devine, Steven
• Granted Patent: US 7,931,726 B2
• Time in Patent Office: Days
• US Class Current: 55/497
• CPC Class Codes: B01D 46/0001 Making filtering elements
• CPC Class Codes: B01D 46/10 Particle separators, e.g. dust precipitators, using filter plates, sheets or pads having plane surfaces
• CPC Class Codes: B01D 46/121 V-type arrangements
• CPC Class Codes: B01D 46/521 using folded, pleated material
• CPC Class Codes: B01D 46/58 connected in parallel
• CPC Class Codes: Y10S 264/48 Processes of making filters
• CPC Class Codes: Y10S 55/05 Methods of making filter
• CPC Class Codes: Y10S 55/31 Filter frame

Abstract

Embodiments of the invention generally include a filter assembly having a media pack having a single web of pleated media having at least two mini-seated regions arranged in non-linear orientation. In one embodiment, a filter assembly includes a media pack defined by a single web of media, and an adhesive layer coupling a flat end of the media pack to a frame assembly to from a lap joint. In another embodiment, a filter assembly includes a media pack sealed to a frame assembly. A discontinuous layer of adhesive couples at least one edge of the media pack to the frame assembly.

Claims

1. A filter assembly comprising:

a frame assembly;

a media pack having a single web of pleated media having at least two mini-pleated regions arranged in non-linear orientation; and

an adhesive layer coupling a flat end of the media pack to the frame assembly.

2. The filter assembly of claim 1, wherein the media is at least one of synthetic filter media, cellulous filter media, wet laid fiber glass filter media or fiber glass filter media.

3. The filter assembly of claim 1, wherein the filter media further comprises:

a filtering layer; and

a backing layer.

4. The filter assembly of claim 3, wherein the backing layer is metal.

5. The filter assembly of claim 3, wherein the backing layer is a wire grid.

6. The filter assembly of claim 1, wherein the frame assembly further comprises:

a top panel;

a bottom panel; and

two side panels coupled to form a quadrilateral.

7. The filter assembly of claim 8, wherein the frame assembly further comprises:

two tabs extending from opposite sides of the frame assembly having the flat end coupled thereto by a lap joint.

8. The filter assembly of claim 1, wherein the frame assembly further comprises:

a wall defining a side of the filter assembly; and

a flange extending inward from the wall, wherein the tab is coupled to the flange.

9. The filter assembly of claim 8, wherein the flange further comprises:

an outer wall having a first end coupled to the wall; and

an inner wall.

10. The filter assembly of claim 9, wherein the tab is oriented between about 30 and to about 90 degrees relative to the wall.

11. The filter assembly of claim 7, wherein the tabs are at least 1.0 inches long.

12. The filter assembly of claim 8, wherein the tab has a length greater than a length of the flange.

13. The filter assembly of claim 9, wherein the tab extends at least as far or further from the wall than the flange.

14. The filter assembly of claim 1 further comprising:

an adhesive layer coupling an open end of the media pack to the frame.

15. The filter assembly of claim 14, wherein one or more strings of adhesive is dispensed in a substantially swirling pattern.

16. The filter assembly of claim 14, wherein the adhesive layer has a zig-zag pattern is disposed on the frame in at least one V-shaped pattern.

17. The filter assembly of claim 15, wherein the adhesive layer further comprises:

one or more adhesive strings having interspersed touching and separated portions.

18. The filter assembly of claim 14, wherein the adhesive layer is a hot melt.

19. A filter assembly comprising:

a frame assembly having first and section tabs extending from opposite sides of the frame assembly;

a media pack having a single web of pleated media having a first flat end coupled a lap joint to the first tab and a second flat end coupled to the second tab, the media pack having at least two mini-pleated regions arranged in v-bank orientation;

at least one channel extending across opposite sides of the frame assembly; and

a form extending from the channel into the area defined between adjacent mini-pleat regions.

20. A filter assembly comprising:

a frame assembly having first and section tabs extending from opposite sides of the frame assembly;

a media pack having a single web of pleated media having at least two mini-pleated regions arranged in v-bank orientation;

hot melt adhesive forming a first lap joint between a first flat end of the media pack and the first tab and a second lap joint between a second flat end of the media pack and the second tab;

at bank separator extending across opposite sides of the frame assembly and into the area defined between adjacent mini-pleat regions; and

an adhesive layer coupling a open end of the media pack to one side the frame assembly, wherein the adhesive layer has a weight of less than about 50 grams/square foot.