Method of making a filter assembly
First Claim
Patent Images
1. A method for fabricating a filter assembly, comprising:
- securing flat ends of a pleated media pack respectively to a first panel and a second panel of a frame assembly via a lap joint, wherein the lap joint is formed by contacting one of the flat ends with an adhesive to a tab respectively extending from the first panel and second panel of the frame assembly such that the adhesive is positioned between the one of the flat ends of the media pack and the tab, wherein each panel frame assembly comprises a side wall defining an outside wall of the frame assembly, an outer wall extending inward from the side wall and defining an upstream flange, and an inner wall connected to the outer wall by a fold, wherein the tab extends inward from the inner wall relative to the side wall and away from the upstream flange, the tab terminating inward of the fold formed in the tab relative to the side wall, the media pack having at least two mini-pleated regions arranged in v-bank orientation; and
securing open ends of the pleated media pack respectively to a top and a bottom of the frame assembly.
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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-pleated 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 form 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.
48 Citations
24 Claims
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1. A method for fabricating a filter assembly, comprising:
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securing flat ends of a pleated media pack respectively to a first panel and a second panel of a frame assembly via a lap joint, wherein the lap joint is formed by contacting one of the flat ends with an adhesive to a tab respectively extending from the first panel and second panel of the frame assembly such that the adhesive is positioned between the one of the flat ends of the media pack and the tab, wherein each panel frame assembly comprises a side wall defining an outside wall of the frame assembly, an outer wall extending inward from the side wall and defining an upstream flange, and an inner wall connected to the outer wall by a fold, wherein the tab extends inward from the inner wall relative to the side wall and away from the upstream flange, the tab terminating inward of the fold formed in the tab relative to the side wall, the media pack having at least two mini-pleated regions arranged in v-bank orientation; and securing open ends of the pleated media pack respectively to a top and a bottom of the frame assembly. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A method for fabricating a filter assembly, comprising:
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securing flat ends of a pleated media pack respectively to a first panel and a second panel of a frame assembly, wherein each panel frame assembly comprises a side wall defining an outside wall of the frame assembly, an outer wall extending inward from the side wall and defining an upstream flange, and an inner wall connected to the outer wall by a fold, wherein a tab extends inward from the inner wall relative to the side wall and away from the upstream flange, the tab terminating inward of the fold formed in the tab relative to the side wall, the media pack having at least two mini-pleated regions arranged in v-bank orientation; applying an adhesive in a swirled pattern to a top and a bottom of the frame assembly; and contacting open ends of the pleated media pack with the swirled adhesive. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21)
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22. A method for fabricating a filter assembly, comprising:
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securing flat ends of a pleated media pack respectively to a first panel and a second panel of a frame assembly, wherein each panel frame assembly comprises a side wall defining an outside wall of the frame assembly, an outer wall extending inward from the side wall and defining an upstream flange, and an inner wall connected to the outer wall by a fold, wherein a tab extends inward from the inner wall relative to the side wall and away from the upstream flange, the tab terminating inward of the fold formed in the tab relative to the side wall, the media pack having at least two mini-pleated regions arranged in v-bank orientation; forming a discontinuous adhesive layer having less than about 50 grams/square foot on a bottom of the frame assembly; and contacting an open end of the pleated media pack with the discontinuous adhesive layer. - View Dependent Claims (23, 24)
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Specification