Abstract: Methods of processing filter media sheets to provide geometries therein are provided. Tooling for use in the methods are also provided. The tooling has a low static coefficient of friction relative to the filter media sheet and a sufficient wetting contact angle to prevent sticking of the filter media sheet to the tooling so as to avoid damaging the filter media sheet and to provide consistently formed geometries in the filter media sheet.

Abstract: A filter includes a pleated filter material with a plurality of pleats arranged circumferentially. The pleated filter material includes a top half and a bottom half. An end cap is coupled with an axial end of the pleated filter material bottom half, and at least a portion of the pleated filter material is tapered. With a smaller end cap, the filter has less area on which dust can accumulate.

Abstract: Disclosed in this specification is a method for making a pleated filter cartridge by placing a pleated filter on a mold and adding a polymerizable potting compound to the inner cavity of the pleated filter. The potting compound is permitted to cover the portion of the upper surface of the mold that is encompassed by the pleats. The potting compound is selected to form a polyurethane after polymerization is complete.

Abstract: A filter core includes a tubular body that has a first end and a second end. The tubular body includes a plurality of surface features spaced longitudinally along the tubular body between the first and second ends. Each of the surface features includes a first portion for flow area and a second portion for bridging across an opening for strength.

Abstract: Certain embodiments of the invention may include filters and methods for imparting structural support to a pleated filter material. According to an example embodiment, the method includes forming a filter structure from one or more sections of pleated filter media, wherein the filter structure comprises one or more filter pleats. The method also includes extruding a banding material to form one or more radial support regions in at least circumferential contact with at least one of an inner or an outer surface of the filter structure, and maintaining spacing between the one or more filter pleats of the filter structure with the one or more radial support regions.

Abstract: Disclosed in this specification is a method for making a pleated filter cartridge by placing a pleated filter on a mold and adding a polymerizable potting compound to the inner cavity of the pleated filter. The potting compound is permitted to cover the portion of the upper surface of the mold that is encompassed by the pleats. The potting compound is selected to form a polyurethane after polymerization is complete.

Abstract: A filter core includes a tubular body that has a first end and a second end. The tubular body includes a plurality of surface features spaced longitudinally along the tubular body between the first and second ends. Each of the surface features includes a first portion for flow area and a second portion for bridging across an opening for strength.

Abstract: A filtration system is provided. The filtration system includes a flexible attachment portion, the attachment portion configured to couple the bag filter to a tube sheet, an adapter ring attached to the attachment portion, and a bag filter attached to the adapter ring.

Abstract: Certain embodiments of the invention may include filters and methods for imparting structural support to a pleated filter material. According to an example embodiment, the method includes forming a filter structure from one or more sections of pleated filter media, wherein the filter structure comprises one or more filter pleats. The method also includes extruding a banding material to form one or more radial support regions in at least circumferential contact with at least one of an inner or an outer surface of the filter structure, and maintaining spacing between the one or more filter pleats of the filter structure with the one or more radial support regions.

Abstract: A coreless filter cartridge includes a filtration media having a plurality of pleats formed in a tubular configuration. The filtration media includes a first end that extends to a second end through an intermediate portion having an exterior surface and an interior surface that defines a hollow core. At least one retention device is adhered to the exterior surface of the filtration media. The at least one retention device is configured and disposed to limit radial movement of the filtration media. The filter cartridge is devoid of an internal core support provided within the hollow core thereby establishing a coreless filter cartridge.

Abstract: A filter cartridge that includes a filter media. The media is pleated and the pleats are arranged into a tube about an axis with a first pleat proximate a last pleat. The filter cartridge includes a strap that has first and second end portions and that extends at least one revolution around the pleated media tube in a helix such that the first and second end portions of the strap are axially displaced from each other. The first and last pleats of the media are attached to each other and the first and second end portions of the strap are attached to the media. The filter cartridge may be made by an associated method. In one specific example, a stitching attaches the strap to the media.

Abstract: A filter element for removing particles from a particulate laden fluid stream includes, in an exemplary embodiment, a filtration media formed into a tubular configuration and that a plurality of circumferentially spaced apart pleats. The filter element also includes at least one melt-extruded retention strap extending circumferentially around the filtration media to limit radial movement of the filtration media at operating temperatures up to about 500° F. Each melt-extruded retention strap is formed from a melt extrudable amorphous thermoplastic polyimide.

Abstract: A filter element includes, in an exemplary embodiment, a first end cap, a second end cap, and a composite filter media structure. The composite filter media structure includes a base substrate that includes a nonwoven synthetic fabric formed from a plurality of bicomponent synthetic fibers with a spunbond process, and having a bond area pattern having a plurality of substantially parallel discontinuous lines of bond area. The base substrate having a minimum filtration efficiency of about 50%, measured in accordance with ASHRAE 52.2-1999 test procedure. The composite filter media structure also includes a nanofiber layer deposited on one side of the base substrate by an by electro-blown spinning process. The composite filter media structure having a minimum filtration efficiency of about 75%, measured in accordance with ASHRAE 52.2-1999 test procedure. The composite media structure further includes a plurality of corrugations formed at a temperature of about 90° C. to about 140° C.

Abstract: A filter element for removing particles from a particulate laden fluid stream includes, in an exemplary embodiment, a filtration media formed into a tubular configuration and that a plurality of circumferentially spaced apart pleats. The filter element also includes at least one melt-extruded retention strap extending circumferentially around the filtration media to limit radial movement of the filtration media at operating temperatures up to about 500° F. Each melt-extruded retention strap is formed from a melt extrudable amorphous thermoplastic polyimide.

Abstract: A method of making a composite filter media includes, in an exemplary aspect, forming a nonwoven fabric substrate that includes a plurality of bicomponent synthetic fibers by a spunbond process, calendering the nonwoven fabric substrate with embossing calender rolls to form a bond area pattern having a plurality of substantially parallel discontinuous lines of bond area to bond the synthetic bicomponent fibers together to form a nonwoven fabric. The nonwoven fabric having a minimum filtration efficiency of about 50%, measured in accordance with ASHRAE 52.2-1999 test procedure. The method also includes applying a nanofiber layer by electro-blown spinning a polymer solution to form a plurality of nanofibers on at least one side of the nonwoven fabric. The composite filter media having a filtration efficiency of at least about 75%, measured in accordance with ASHRAE 52.2-1999 test procedure.

Abstract: A filter element includes, in an exemplary embodiment, a first end cap, a second end cap, and a composite filter media structure. The composite filter media structure includes a base substrate that includes a nonwoven synthetic fabric formed from a plurality of bicomponent synthetic fibers with a spunbond process, and having a bond area pattern having a plurality of substantially parallel discontinuous lines of bond area. The base substrate having a minimum filtration efficiency of about 50%, measured in accordance with ASHRAE 52.2-1999 test procedure. The composite filter media structure also includes a nanofiber layer deposited on one side of the base substrate by an by electro-blown spinning process. The composite filter media structure having a minimum filtration efficiency of about 75%, measured in accordance with ASHRAE 52.2-1999 test procedure. The composite media structure further includes a plurality of corrugations formed at a temperature of about 90° C. to about 140° C.

Abstract: A filter cartridge comprises a pleat pack including filtration media for removing particulates from a particulate laden fluid stream moving in a first direction through the filtration media. The pleat pack is formed into a tubular configuration with a plurality of circumferentially spaced pleats. The filtration media is periodically subject to a cleaning fluid stream moving in a second direction opposite to the first direction. Potting material is at axially opposite end portions of the pleat pack to maintain the filtration media in the tubular configuration. A support tube is located on a first side of the pleat pack downstream of the filtration media in the first direction of fluid flow. A retention device limits movement of a portion of the filtration media when subjected to the periodic cleaning fluid stream. The retention device comprises a metal band and located on a second side of the filtration media opposite the first side.

Abstract: A composite filter media structure is provided. In an exemplary embodiment, the composite filter media structure includes a corrugated base substrate that includes a nonwoven synthetic fabric formed by a dry-laid process that corrugates the base substrate during the forming process. The composite filter media structure also includes a nanofiber membrane deposited on at least one side of the base substrate by an electro-blown spinning process.

Abstract: A method of fabricating a filter cartridge includes providing filtration media formed into a plurality of pleats, wherein the filtration media have a substantially tubular configuration with a pre-determined circumferential spacing between each of the plurality of pleats. The filter cartridge is configured to remove particulates from a particulate-laden fluid stream flowing in a direction through the filter cartridge. The filter cartridge is also configured to be periodically subjected to a cleaning fluid stream flowing in a substantially opposite direction of the particulate-laden fluid stream. The method also includes coupling at least one retention device to the filtration media, wherein the retention device is fabricated from a melt-extrudable polymer material that is configured to facilitate extending a life expectancy of the filter cartridge when operationally exposed to operating temperatures ranging from 135° C. (275° F.) to 204° C. (400° F.).

Abstract: The present invention provides a method of preparing a support for a filtration medium comprising passing a sheet of nonwoven fibrous polymeric material having first and second sides through a calender which comprises a nondeformable roll and a resilient roll, the nondeformable roll being maintained at a temperature below the melting temperature of the material, so as to increase the smoothness of the first side of the material which contacted the resilient roll. A filtration medium support material prepared in accordance with the method of the present invention, as well as a filter comprising a filtration medium and that filtration medium support material, are also provided by the present invention.