Abstract: A filter element and filter apparatus, and a method for fabricating a filter element, include a filter element having alternating layers of a face sheet material and a convoluted filter material, with the alternating layers forming substantially longitudinally oriented flutes that extend axially along, or past, a radially acting seal, into previously unused portions of the cavity of a filter housing. In some embodiments, structures such as struts extending partially across an outlet end of the filter element, or a rigid web formed by a layer of resin extending axially a potted length into pome of the flutes from the outlet end resist axially oriented pressure forces on the alternating layers.

Abstract: A filter element and filter apparatus, and a method for fabricating a filter element, include a filter element having alternating layers of a face sheet material and a convoluted filter material, with the alternating layers forming substantially longitudinally oriented flutes that extend axially along, or past, a radially acting seal, into previously unused portions of the cavity of a filter housing. In some embodiments, structures such as struts extending partially across an outlet end of the filter element, or a rigid web formed by a layer of resin extending axially a potted length into pome of the flutes from the outlet end resist axially oriented pressure forces on the alternating layers.

Abstract: The invention describes an improved process for the sealing of alternating flutes of ‘honeycomb’ designed filters to be made after construction, or fabrication, of the basic filter structure, rather than during construction, as is shown in the prior art. The method seals both sides of the primary flutes as is typically done for one side in the prior art and then the media is rolled into a honeycomb shape so that secondary flutes, open on both sides of the roll are created. The roll is vertically orientated and then the lower end is immersed into a sealing compound to such a depth which will cause the sealing compound to travel up into the lower portion of the roll to a height above the height of the lower seal for the primary flutes. The sealing compound is allowed to cure, effectively sealing the secondary flutes. The roll is then cut along a line located above the height of the lower seal for the primary flutes and before the top surface of the sealing compound in the secondary flutes.

Abstract: The invention describes an improved process for the sealing of alternating flutes of ‘honeycomb’ designed filters to be made after construction, or fabrication, of the basic filter structure, rather than during construction, as is shown in the prior art. The method seals both sides of the primary flutes as is typically done for one side in the prior art and then the media is rolled into a honeycomb shape so that secondary flutes, open on both sides of the roll are created. The roll is vertically orientated and then the lower end is immersed into a sealing compound to such a depth which will cause the sealing compound to travel up into the lower portion of the roll to a height above the height of the lower seal for the primary flutes. The sealing compound is allowed to cure, effectively sealing the secondary flutes. The roll is then cut along a line located above the height of the lower seal for the primary flutes and before the top surface of the sealing compound in the secondary flutes.

Abstract: A filter having a structural framework (45) formed integral with and surrounding an active filtering area, and a process for manufacturing the filter are disclosed. The process includes (a) masking selected areas (40) on a sheet (30) of filter media, which areas will serve as the active filtering areas in the end filter product; (b) applying to the remaining exposed areas of the media a liquid-phase filler material; (c) forcing the material to fully penetrate and completely saturate the exposed media areas; (d) and curing the filler-saturated media areas whereby the filler material solidifies within the fiber structure of the media making that portion of the media sheet impervious to any air flow therethrough. The sealed media area (45) provides a structurally integral framework which is continuous with the active filtering media area (40) of the filter. The filter may then be secured along its integral framework area (45) to a suitable mounting substrate surface.

Abstract: A fluid filtering device in various embodiments is disclosed. The filter includes, in one embodiment, alternating layers (34, 36) of flat and corrugated filter media which are rolled together and sealed at alternate ends by sealant (38, 42). Further embodiments disclose filter packs (112, 212, 312) of alternating layers of flat and corrugated filter media. In one embodiment, corrugations of successive layers are aligned in parallel. In an alternate embodiment corrugations are aligned orthogonally. Unfiltered fluids enter tubular passages (44) for example, and must exit by adjacent passages either above, below or beside the flute of entry to exit the filter. Filtering occurs when the fluid crosses a sidewall of filter media.