Filter assembly with full cross section

Abstract

The present application relates to filter assemblies utilizing full cross-section. A filter assembly includes a filter housing defining an interior volume having an inner cross-section defining an inner cross-sectional distance, the filter housing having a base and a sidewall. A filter element is disposed within the interior volume. The filter element includes a filter media pack, at least a portion of the filter media pack having an outer cross-section defining an outer cross-sectional distance, the outer cross-sectional distance being substantially equal to the inner cross-sectional distance of the interior volume of the filter housing. A support structure is coupled to at least one longitudinal end of the filter media pack.

Description

[0001] This application is a divisional application of the application filed on June 28, 2019, with application number 201980097744.0 and invention title "Filter Assembly with Full Cross-Section". Technical Field

[0002] This disclosure generally relates to filters for use with internal combustion engine systems. background

[0003] Internal combustion engines typically use various fluids during operation. For example, fuel (e.g., diesel, gasoline, natural gas, etc.) is used to power the engine. Air can be mixed with fuel to create an air-fuel mixture, which the engine then uses to operate under stoichiometric or lean-burn conditions. Additionally, one or more lubricants can be supplied to the engine to lubricate its various components (e.g., piston cylinders, crankshaft, bearings, gears, valves, camshafts, etc.). These fluids can be contaminated with particulate matter (e.g., carbon, dust, metal particles, etc.), which, if not removed from the fluid, can damage engine components. To remove such particulate matter or other contaminants, the fluid typically passes through a filter assembly (e.g., fuel filter, lubricant filter, air filter, water filter assembly, etc.), which is configured to remove particulate matter from the fluid before delivery. Pressure loss or leakage in the filter assembly can reduce its filtration efficiency. Overview

[0004] The embodiments described herein generally relate to filter assemblies including a filter media package that fits tightly within a filter housing of the filter assembly to provide a seal against at least a portion of the sidewalls of the filter housing. The embodiments described herein also generally relate to forward-flow and reverse-flow filter assemblies, axial-flow filter elements, axial-to-radial-flow filter elements, filter elements with variable cross-sections, and coalescing filter assemblies including axial-flow filter media.

[0005] In a first set of embodiments, a filter assembly includes a filter housing defining an internal volume having an inner cross-section defining an inner cross-sectional distance, the filter housing having a base and sidewalls. A filter element is disposed within the internal volume. The filter element includes a filter media package, at least a portion of which has an outer cross-section defining an outer cross-sectional distance substantially equal to the inner cross-sectional distance of the internal volume of the filter housing. A support structure is coupled to at least one longitudinal end of the filter media package.

[0006] In some embodiments, the support structure is coupled to a longitudinal end of the filter media pack, at which fluid exits the filter media pack after passing through it.

[0007] In some embodiments, the support structure includes: a first support structure connected to a first longitudinal end of the filter media package remote from the base; and a second support structure connected to a second longitudinal end of the filter media package opposite to the first longitudinal end.

[0008] In some embodiments, the filter media package includes tetrahedral media.

[0009] In some embodiments, the outer cross-section of the filter media package is circular.

[0010] In some embodiments, the filter media package includes an axial flow filter media package configured to allow fluid to flow through the axial flow filter media package along the longitudinal axis of the filter assembly.

[0011] In some embodiments, each of the first support structure and the second support structure includes a grid or mesh.

[0012] In some embodiments, a sealing member is disposed between the filter element and the sidewall of the filter housing at a longitudinal end opposite to the longitudinal end where the support structure is disposed, near the filter media pack, thereby preventing fluid from flowing around the filter media pack.

[0013] In some embodiments, the filter housing further includes an outlet chamber formed between the second support structure and the base, wherein an outlet is disposed in the outlet chamber to allow filtered fluid to exit the filter housing.

[0014] In some embodiments, the filter assembly further includes a cap coupled to an end of the filter housing remote from the base, with an inlet defined in the cap to allow fluid to enter the filter housing.

[0015] In some embodiments, the filter media package is formed of filter media comprising: a filter media layer folded along its folding axis such that a first edge of the filter media layer is close to an opposite edge of the filter media layer after folding, and a filter bag formed of the filter media layer, the filter bag being configured to receive unfiltered fluid; and an inflow mesh disposed in the filter bag.

[0016] In some embodiments, the filter media layer is bonded along the fold axis to at least itself or the inflow mesh.

[0017] In some embodiments, the filter medium further includes an outflow mesh disposed on the surface of the filter medium layer outside the filter bag portion.

[0018] In some embodiments, the filter media package comprises a cylindrical roll of the filter media layer wound along its fold axis.

[0019] In some embodiments, the filter media package includes a plurality of filter media layers providing a plurality of filter bag-like portions, each of the plurality of filter bag-like portions having an outflow mesh disposed therebetween.

[0020] In some embodiments, the filter assembly further includes an upstream filter medium disposed upstream of the filter element.

[0021] In another embodiment, a filter assembly includes a filter housing defining an internal volume having an inner cross-section defining an inner cross-sectional distance, the filter housing having a base and sidewalls. A filter element is disposed within the internal volume. The filter element includes an axial flow filter media package. A channel is defined along the longitudinal axis of the filter assembly through the axial flow filter media package. The axial flow filter media package is configured to allow fluid to flow through the filter media package in a first direction along the longitudinal axis and be filtered, the filtered fluid flowing through the channel toward an outlet in a second direction opposite to the first direction. At least a portion of the axial flow filter media package has an outer cross-section defining an outer cross-sectional distance substantially equal to the inner cross-sectional distance of the internal volume of the housing. A support structure is coupled to at least one end of the axial flow filter media package.

[0022] In some embodiments, the support structure is coupled to an end of the axial flow filter media package, at which the fluid exits the axial flow filter media package after passing through it.

[0023] In some embodiments, the support structure includes: a first support structure connected to a first end of the axial flow filter media package; and a second support structure connected to a second end of the axial flow filter media package opposite to the first end.

[0024] In some embodiments, the outer cross-sectional distance of the axial flow filter media package includes the sum of the following: (a) the cross-sectional width of the channel; (b) a first radial distance from the inner surface of the axial flow filter media package forming the channel at a first location to the outer surface of the axial flow filter media package near the first location; and (c) a second radial distance from the inner surface of the axial flow filter media package at a second location opposite to the first location to the outer surface of the axial flow filter media package near the second location.

[0025] In some embodiments, the axial flow filter media package includes tetrahedral media.

[0026] In some embodiments, the outer cross-section of the axial flow filter media package is circular.

[0027] In some embodiments, the filter element further includes a central tube positioned within the channel, with one end of the central tube connected to the outlet.

[0028] In some embodiments, the filter assembly further includes a cap coupled to an end of the filter housing opposite the base, such that an inlet chamber is defined between the first support structure and the cap, the base being at a lower height relative to the cap, the cap defining the outlet of the filter housing and an inlet for allowing fluid to enter the inlet chamber, the outlet being fluidly sealed to the inlet chamber, wherein a flow reversal chamber is defined between the second support structure and the base, in which filtered fluid changes its flow direction from the first direction toward the second direction.

[0029] In some embodiments, the filter assembly further includes a discharge port disposed in the flow reversal chamber for discharging liquid collected in the flow reversal chamber.

[0030] In some embodiments, the first support structure and the second support structure include a grid or mesh.

[0031] In some embodiments, a sealing member is disposed between the first support structure and the sidewall of the filter housing to prevent fluid from flowing around the axial flow filter media package.

[0032] In some embodiments, the filter assembly further includes a cap coupled to an end of the filter housing opposite the base, such that an inlet chamber is defined between the second support structure and the cap, the cap being positioned at a lower height relative to the base, the cap defining an inlet for allowing fluid to enter the inlet chamber and an outlet, the outlet being fluidly sealed to the inlet chamber, wherein a flow reversal chamber is defined between the first support structure and the base, in which filtered fluid changes its flow direction from the first direction toward the second direction.

[0033] In some embodiments, the filter assembly further includes a discharge port disposed in the inlet chamber for discharging liquid collected in the inlet chamber.

[0034] In some embodiments, the first support structure and the second support structure include a grid or mesh.

[0035] In some embodiments, a sealing member is disposed between the second support structure and the sidewall of the filter housing to prevent fluid from flowing around the filter medium.

[0036] In some embodiments, the axial flow filter media package is formed of filter media comprising: a filter media layer folded along its folding axis such that a first edge of the filter media layer is close to an opposite edge of the filter media layer after folding, and a filter bag formed by the filter media layer, the filter bag being configured to receive unfiltered fluid; and an inflow mesh disposed in the filter bag.

[0037] In some embodiments, the filter media layer is bonded along the fold axis to at least itself or the inflow mesh.

[0038] In some embodiments, the axial flow filter media package further includes an outflow mesh disposed on the surface of the filter media layer outside the filter bag portion.

[0039] In some embodiments, the axial flow filter media package comprises a cylindrical roll of the filter media layer wound along its fold axis.

[0040] In another set of embodiments, a filter element is provided, configured to be disposed within a filter housing having an inner cross-section defining a maximum inner cross-sectional distance. The filter element includes a filter media package, at least a portion of which has an outer cross-section defining a maximum outer cross-sectional distance substantially equal to the maximum inner cross-sectional distance of the internal volume of the filter housing. A support structure is coupled to at least one longitudinal end of the filter media package.

[0041] In another set of embodiments, a filter element is provided, configured to be disposed within a filter housing having an inner cross-section defining an inner cross-sectional distance. An axial flow filter media package is provided. A channel is defined through the axial flow filter media package along the longitudinal axis of the filter element. The axial flow filter media package is configured to allow fluid to flow through and be filtered in a first direction along the longitudinal axis, with the filtered fluid flowing through the channel toward an outlet in a second direction opposite to the first direction. At least a portion of the axial flow filter media package has an outer cross-section defining an outer cross-sectional distance substantially equal to the inner cross-sectional distance of the internal volume of the housing. A support structure is coupled to at least one end of the axial flow filter media package.

[0042] It should be understood that all combinations of the foregoing concepts and other concepts discussed in more detail below (provided these concepts do not contradict each other) are contemplated as part of the subject matter disclosed herein. In particular, all combinations of the claimed subject matter appearing at the end of this disclosure are contemplated as part of the subject matter disclosed herein. Brief description of the attached diagram

[0043] The foregoing and other features of this disclosure will become more apparent from the accompanying drawings, the following description, and the appended claims. It should be understood that these drawings depict only a few embodiments according to this disclosure and are therefore not intended to limit its scope; the disclosure will be described with additional features and details using the drawings.

[0044] Figure 1 This is a schematic diagram of a filter assembly according to an embodiment.

[0045] Figure 2 This is a perspective view of a pleated filter medium defining multiple tetrahedral channels according to an embodiment.

[0046] Figure 3 It is an enlarged perspective view of a pleated filter medium that defines multiple tetrahedral channels.

[0047] Figure 4 Shown from the entrance end Figure 2 The pleated filter media.

[0048] Figure 5 It is shown from the outlet end Figure 2 The pleated filter media.

[0049] Figure 6 This is an exploded perspective view showing a portion of a pleated filter medium with defined tetrahedral channels according to an embodiment.

[0050] Figure 7 This is an enlarged perspective view showing a portion of a pleated filter medium with defined tetrahedral channels according to an embodiment.

[0051] Figure 8 Similar to Figure 6 And it is a view taken from the opposite ends.

[0052] Figure 9 This is a perspective view illustrating one embodiment of a pleated filter according to an example.

[0053] Figure 10 This is a perspective view showing another embodiment of the pleated filter medium according to an embodiment.

[0054] Figure 11 This is an end view showing another embodiment of the pleated filter medium according to an example.

[0055] Figure 12 It further demonstrates Figure 11 A perspective view of the implementation method.

[0056] Figure 13 It is along Figure 12 The sectional view taken from line 12-12.

[0057] Figure 14 Similar to Figure 6 and Figure 7 Another embodiment is shown.

[0058] Figure 15 Similar to Figure 8 And from Figure 14 A view taken from the opposite ends.

[0059] Figure 16 Similar to Figure 6 And further demonstrated Figure 14 The structure of.

[0060] Figure 17A This is a schematic diagram of a filter assembly including filter elements according to an embodiment.

[0061] Figure 17B According to the embodiments, it is possible to Figure 17AA perspective view of the filter media package used in the filter components.

[0062] Figure 17C According to another embodiment, it is possible to Figure 17A A perspective view of the filter media package used in the filter components.

[0063] Figure 18 According to the embodiments Figure 17A A side cross-sectional view of the filter element.

[0064] Figure 19 This is a schematic diagram of a filter assembly including filter elements according to another embodiment.

[0065] Figure 20 According to the embodiments Figure 19 A side cross-sectional view of the filter element.

[0066] Figure 21 This is a top perspective view of the first filter media layer that can be used in a filter media package.

[0067] Figure 22 This is a top perspective view of a wound filter media package according to an embodiment, a portion of which is unfolded to show the various layers included therein.

[0068] Figure 23 This is a top perspective view of a wound filter media package according to another embodiment, a portion of which is unfolded to show the various layers included therein.

[0069] Figures 24-28 This is a schematic diagram illustrating various operations that can be used to form a filter bag from a filter media layer, according to various embodiments.

[0070] Figure 29 This is a schematic diagram of a filter element including a folded filter medium according to an embodiment.

[0071] Figure 30 This is a schematic diagram of a filter element including a folded filter medium according to another embodiment.

[0072] Figure 31 This is a perspective view of a filter element according to an embodiment.

[0073] Figure 32 This is a top perspective view of a wound filter media package according to another embodiment, a portion of which is unfolded to show the various layers included therein.

[0074] Figure 33 Showing the wound Figure 32 Filter media package.

[0075] Figure 34 This is a side cross-sectional view of a portion of a filter media package according to yet another embodiment.

[0076] Figure 35 This is a top cross-sectional view of a filter media package according to an embodiment, the filter media package comprising multiple filter media layers of different lengths, these filter media layers being connected to each other and sized to form an elongated oval filter media.

[0077] Figure 36 This is a top cross-sectional view of a filter media package according to another embodiment, the filter media package comprising a filter media layer folded multiple times to form an elongated oval filter media package.

[0078] Figure 37 This is a schematic diagram of a filter element according to an embodiment, the filter element including a main filter media package having a first width and a downstream filter media package having a second width less than the first width.

[0079] Figure 38 This is a schematic diagram of a filter element, which includes a main filter media package having a first width, an upstream filter media package having a second width greater than the first width, and a downstream filter media package having a third width less than the first width.

[0080] Figure 39 This is a schematic diagram of a reverse flow filter element according to another embodiment.

[0081] Figure 40 This is a schematic diagram of a rotary filter element configured to filter fuel or oil according to an embodiment.

[0082] Figure 41 This is a schematic diagram of a coalescing filter element including an axial flow filter medium according to another embodiment.

[0083] Figure 42 It is included according to the embodiments Figure 41 The filter media package in the coalescing filter assembly is along Figure 41 The diagram shows a side cross-section taken from line XX.

[0084] Figure 43 Is included Figure 41 A top cross-sectional view of the filter media package in the coalescing filter assembly.

[0085] Figure 44 Is included Figure 41 A portion of the filter media package in the coalescing filter assembly runs along Figure 42The side cross-section diagram taken from line YY in the figure.

[0086] Figures 45-47 This is a side cross-sectional view of a filter assembly according to various embodiments.

[0087] Figure 48 This is a front perspective view of the filter media package according to an embodiment.

[0088] Figure 49 This is a front view of a filter media package according to another embodiment.

[0089] Figure 50 It is for accommodating according to the embodiment Figure 51 Side perspective view of the filter housing of the filter element.

[0090] Figure 51 This is a perspective view of a rolled-up filter media package including a backing sheet and a filter media layer according to an embodiment.

[0091] Figure 52 It is in a flat configuration Figure 51 A perspective view of the backing sheet.

[0092] Figure 53 This is a side perspective view of the filter media package, with the backing sheet and filter media layer partially unfolded.

[0093] Figure 54 It is along Figure 53 The line AA in the middle is intercepted Figure 53 A side cross-sectional view of the filter media package.

[0094] Reference is made to the accompanying drawings throughout the detailed description below. In the drawings, similar symbols generally denote similar parts unless the context otherwise indicates. The illustrative embodiments described in the detailed description, drawings, and claims are not intended to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that, as generally described herein and shown in the drawings, aspects of this disclosure can be arranged, substituted, combined, and designed in a variety of different configurations, all of which are expressly contemplated and are part of this disclosure. Detailed Explanation

[0095] The embodiments described herein generally relate to filter assemblies including a filter media package that fits tightly within a filter housing of the filter assembly to provide a seal against at least a portion of the sidewalls of the filter housing. The embodiments described herein also generally relate to forward-flow and reverse-flow filter assemblies, axial-flow filter elements, axial-to-radial-flow filter elements, filter elements with variable cross-sections, and coalescing filter assemblies including axial-flow filter media packages.

[0096] The embodiments of the filter assemblies and filter media described herein may provide one or more benefits, including, for example, (1) preventing leakage of liquid flowing around the filter media package by providing a filter media package that substantially occupies all the cross-sectional area within the filter housing, for example, the filter media package being smaller than the cross-sectional area or inner cross-sectional dimension of the filter housing (e.g., 1% to 10%, including 1% and 10%, of the cross-sectional width of the filter housing in which the filter media package is disposed), thus providing better space utilization for contaminant removal, enhancing the retention of the filter media, increasing capacity, and reducing surface velocity and pressure drop; (2) allowing forward flow. (2) Or a reverse flow configuration is implemented; (3) by providing fully synthetic nanofiber media that are paired with the wound inflow and outflow mesh layers, the packing density of the filter media is increased and the maintenance cycle is increased; (4) the expansion and contraction of the wound filter media package via the outflow mesh layer is prevented; (5) the filter media including filter bag-like portions is provided to improve filtration efficiency and facilitate packaging; (6) the bulging of the wound filter media package is prevented via point joints, protrusions or ribs; (7) tandem filtration is allowed using axial flow filter media in forward or reverse flow configurations; and (8) droplet separation from fluids (e.g., gases or liquids) is provided via the axial flow filter media package.

[0097] Figure 1 This is a schematic diagram of a filter assembly 100 according to one embodiment. The filter assembly 100 can be used to filter gases (e.g., air) or another fluid supplied to an engine. The filter assembly 100 includes a filter housing 101 and a filter element 110. In some embodiments, the filter element 110 may be a disposable in-line filter including the filter housing 101. In other embodiments, the filter element 110 may include a cylindrical filter element that can be mounted in the filter housing 101.

[0098] Filter housing 101 defines an internal volume having an inner cross-sectional width IC (e.g., diameter, width, length, etc.), within which filter element 110 is positioned. Filter housing 101 (e.g., a shell or container) includes a base 103 and sidewalls 102 projecting perpendicularly from the outer edge of the base 103. The base 103 and sidewalls 102 may be integrally formed. Filter housing 101 may be formed of a robust and rigid material, such as plastics (e.g., polypropylene, high-density polyethylene, polyvinyl chloride, nylon, etc.), metals (e.g., aluminum, stainless steel, etc.), reinforced rubber, silicone, or any other suitable material. In a particular embodiment, filter housing 101 may comprise a cylindrical shell having a generally circular cross-section. In other embodiments, filter housing 101 may have any other suitable cross-sectional shape, such as circular, elliptical, racetrack-shaped, rectangular, square, polygonal, leaf-shaped, asymmetrical, or any other suitable shape. The cross-sectional shape and / or size of the filter element (in this embodiment and in other embodiments described herein) may also vary along its axial length; for example, the cross-section of filter element 110 at one end may have a different shape and / or size than that at its other end. Filter element 110 may have a cross-sectional shape corresponding to the cross-sectional shape of filter housing 101.

[0099] A cap 104 or cover is coupled to the end of the filter housing 101 remote from the base 103. The cap 104 may be removably coupled to the sidewall 102, for example via a threaded, snap-fit ​​mechanism, friction fit, clamp, screw, nut, or any other suitable coupling mechanism. In some embodiments, an inlet 106 may be defined in the cap 104 to allow unfiltered fluid to enter the internal volume of the filter housing 101. In other embodiments, the inlet 106 may be defined in the sidewall 102, near the cap 104. Furthermore, an outlet 108 may be defined in the base 103 to allow filtered fluid to exit the filter housing 101. In other embodiments, the outlet 108 may be defined in the sidewall 102, near the base 103. The cap 104 is removably coupled to the filter housing 101 to allow the filter element 110 to be inserted into and / or removed from the internal volume of the filter housing 101. In other embodiments, the cap 104 and / or base 103 are permanently secured to the remainder of the filter housing 110 such that the filter element 110 cannot be removed from the filter housing 101 without physical damage to it. The cap 104 may be formed of any suitable material, such as metal, plastic, polymer, elastomer, rubber, reinforced rubber, etc. In some embodiments, the filter element 110 may be configured to be coupled to a filter head (e.g., screwed onto a filter head). In such embodiments, the cap 104 can be removed.

[0100] Filter element 110 is located within the internal volume along the longitudinal axis A of filter assembly 100. L Positioning. Filter element 110 includes: a filter medium package 112 formed of filter medium; a first support structure 114 coupled to a first longitudinal end of filter medium package 112 remote from base 103; and a second support structure 116 coupled to a second longitudinal end of filter medium 112 opposite to the first longitudinal end. Although shown as including two support structures 114, 116, in other embodiments, filter element 110 may have a single support structure coupled to a longitudinal end of filter medium package 112 (where fluid exits filter medium package 112 after passing through it), for example, a longitudinal end near base 103.

[0101] The filter media used to form the filter media package 112 comprises a porous material having a predetermined pore size and configured to filter particulate matter from a fluid flowing through it, thereby producing a filtered fluid. In some embodiments, the filter media package 112 may comprise an axial flow filter media configured to allow fluid to flow along its longitudinal axis from a first end near the cap 104 to a second end opposite the first end. In such an embodiment, an inlet chamber 107 is formed between the first support structure 114 and the cap 104. Contaminated fluid enters the inlet chamber 107 through inlet 106 and enters the first end of the filter media package 112 through the first support structure 114. An outlet chamber 109 is also formed between the second support structure 116 and the base 103. The filtered fluid is received in the outlet chamber 109 after passing through the filter element 110 and is allowed to exit the filter housing 101 through an outlet 108 disposed in the outlet chamber 109 (e.g., defined in the base 103).

[0102] In various embodiments, the first support structure 114 may include a grid or mesh configured to facilitate the diffusion of fluid flow across the surface of a first end of the filter media package 112. Furthermore, the second support structure may also include a grid or mesh to facilitate outward fluid flow of filtered fluid discharged from the filter media package 112.

[0103] In some embodiments, the first support structure 114 may have a distance (e.g., diameter, width, length, etc.) corresponding to the distance between the inner cross-section of the filter housing 101 and the outer cross-section of the filter media package 112, such that the radially outer surface of the first support structure 114 contacts the inner surface of the sidewall 102 and forms a fluid-tight seal with the inner surface of the sidewall 102, thereby preventing contaminated fluid from flowing around the filter media package 112. In such embodiments, the first support structure 114 may be formed of a compliant material (e.g., rubber or polymer). In other embodiments, a sealing member 130 is disposed between the first support structure 114 and the sidewall 102 to prevent contaminated fluid from flowing around the filter media package 112. The sealing member 130 may include an O-ring, a gasket, or any other suitable sealing member used as a radial seal, axial seal, or scraping seal.

[0104] At least a portion of the filter media package 112 has an outer cross-section defining an outer cross-sectional distance OC (e.g., diameter or width), which is substantially equal to the inner cross-sectional distance IC (e.g., diameter or width) of the internal volume of the filter housing 101. For example, the filter media package 112 may be a cylindrical filter media or a wound filter media having an outer diameter equal to or greater than 98% of the inner diameter of the filter housing 101. In some embodiments, the distance D between the inner surface of the sidewall 102 and the radial outer surface of the filter media package 112 may range from 0.1 mm to 5 mm. In embodiments where the filter media package 112 has various unequal cross-sections in length or diameter, each cross-section of the filter media package 112 may be substantially equal to the corresponding cross-section of the filter housing 101.

[0105] The outer cross-sectional distance OC of the filter media pack 112 is substantially equal to the inner cross-sectional distance IC of the filter housing 101. This allows at least a corresponding portion of the radially outer surface of the filter media pack 112 to be sufficiently close to the inner surface of the sidewall 102 to provide at least a partial seal, and in some embodiments, also to provide structural support. Furthermore, this allows for more efficient use of the housing's internal volume, providing an increased filter media area for increased capacity, reducing surface velocity and pressure drop, and thus increasing the overall filtration efficiency of the filter assembly 100. It should be understood that, although... Figure 1 The filter media package 112 is shown to have a constant outer cross-section, but in other embodiments, the filter media package 112 may have a variable cross-section (e.g., a tapered cross-section).

[0106] In some embodiments, the filter media package 112 may be enclosed. For example, the filter element 110 may also include a porous rigid structure (e.g., a wire mesh) positioned around the filter media package 112 and configured to prevent damage to the filter media package 112 during insertion into and / or removal from the internal volume of the filter element 110.

[0107] The filter media package 112 can have any suitable shape. In some embodiments, the filter media package 112 can have a circular cross-section. In other embodiments, the filter media package 112 can have a square, rectangular, elliptical, racetrack-shaped (having two curved portions connected by two generally straight portions), oblong, polygonal, leaf-shaped, or asymmetrical cross-sectional shape, which can correspond to the inner cross-sectional shape of the housing 101. In some embodiments, the filter media package 112 can include wound filter media comprising one or more layers of filter media wound into a roll (e.g., a spiral roll). In other embodiments, the filter media package 112 can include shaped filter media or stacked filter media comprising a plurality of filter media layers stacked on top of each other to form the filter media package 112.

[0108] The filter media package 112 may include any suitable filter media. In some embodiments, the filter media package 112 may include a tetrahedral media package, for example, a pleated or folded filter media including tetrahedral pleats. In other embodiments, the filter media package 112 may include a grooved media package, a straw-type media package, an origami-type media package, or any other suitable filter media package.

[0109] For example, in a specific embodiment, filter media package 112 may include tetrahedral filter media defined by a plurality of tetrahedral channels, as described in U.S. Patent No. 8,397,920, which is incorporated herein by reference in its entirety. Further elaboration... Figures 2-5 A filter medium 20 is shown that can be used to form a filter medium package 112 for filter element 110. The filter medium 20 has an upstream inlet 22 for receiving incoming dirty fluid (as indicated by arrow 23) and a downstream outlet 24 for discharging clean, filtered fluid (as indicated by arrow 25). The filter medium 20 is pleated along multiple bends 26. The bends extend axially in the axial direction 28 (see...). Figures 2-5The filter medium 20 includes a first set of bends 30 extending from the upstream inlet 22 toward the downstream outlet 24, and a second set of bends 32 extending axially from the downstream outlet 24 toward the upstream inlet 22. The filter medium 20 has a plurality of filter medium wall segments 34 extending meanderingly between the bends. The wall segments extend axially and define axial flow channels 36 therebetween. The channels have a height 38 along a transverse direction 40, which is perpendicular to the axial direction 28 (see [link to relevant documentation]). Figure 3 The channel has a lateral width 42 along a lateral direction 44, which is perpendicular to the axial direction 28 and the transverse direction 40. As the bends extend axially in the axial direction, the distance between at least some of the bends gradually decreases in the transverse direction, as described below.

[0110] The wall segments include the first group of wall segments 46 (see Figure 3 , Figure 4 The first set of wall segments is sealed alternately to each other at the upstream inlet 22, for example by adhesive 48, to define a first set of channels 50 having open upstream ends and a second set of channels 52 intersecting the first set of channels and having closed upstream ends. The wall segments include a second set of wall segments 54 (see...). Figure 4 , Figure 5 The second set of wall sections are sealed to each other alternately at the downstream outlet 24, for example by adhesive 56, to define a third set of channels 58 with closed downstream ends and a fourth set of channels 60 with open downstream ends (see...). Figure 5 The first set of bends 30 includes a first sub-set of bends 62 defining the first set of channels 50 and a second sub-set of bends 64 defining the second set of channels 52. The second sub-set of bends 64 gradually decreases in the transverse direction 40 as they extend axially from the upstream inlet 22 toward the downstream outlet 24 (see...). Figures 6-8 The second set of bends 32 includes a third sub-set of bends 66 defining a third set of channels 58 and a fourth sub-set of bends 68 defining a fourth set of channels 60. The fourth sub-set of bends 68 gradually decreases in the transverse direction 40 as they extend axially from the downstream outlet 24 toward the upstream inlet 22 (see...). Figures 6-8As the second set of channels 52 extends axially along the axial direction 28 toward the downstream outlet 24, the second set of channels 52 has a decreasing lateral channel height 38 along the lateral direction 40. The gradual reduction of the second sub-group bend line 64 in the lateral direction 40 provides for the decreasing lateral channel height 38 of the second set of channels 52. As the fourth set of channels 60 extends axially along the axial direction 28 toward the upstream inlet 22, the fourth set of channels 60 has a decreasing lateral channel height 38 along the lateral direction 40. The gradual reduction of the fourth sub-group bend line 68 in the lateral direction 40 provides for the decreasing lateral channel height 38 of the fourth set of channels 60.

[0111] The incoming dirty fluid 23 to be filtered flows axially 28 into the open channel 50 at the upstream inlet 22 and laterally and / or transversely through the filter media wall section of the pleated filter media 20, then flows axially 28 as clean, filtered fluid 25, passing through the open channel 60 at the downstream outlet 24. A second subgroup bend 64 provides lateral cross-flow 44 across the respective channels downstream of the upstream inlet 22. A fourth subgroup bend 68 provides lateral cross-flow 44 across the respective channels upstream of the downstream outlet 24. The second and fourth subgroup bends 64 and 68 have an axially overlapping section 70, and the lateral cross-flow is provided at least at the axially overlapping section 70.

[0112] The second subgroup of bends 64 gradually narrows to the corresponding termination point 72 (see...). Figures 6-8 The second set of channels 52 provides a minimum lateral channel height 38 at these termination points. The fourth sub-group bend 68 gradually narrows to corresponding termination points 74, providing a minimum lateral channel height 38 for the fourth set of channels 60. The termination point 72 of the second sub-group bend 64 is axially downstream of the termination point 74 of the fourth sub-group bend 68. This provides the axial overlap section 70. In one embodiment, the termination point 72 of the second sub-group bend 64 is at the downstream outlet 24, while in other embodiments it is axially upstream of the downstream outlet 24. In one embodiment, the termination point 74 of the fourth sub-group bend 68 is at the upstream inlet 22, while in other embodiments it is axially downstream of the upstream inlet 22.

[0113] At the upstream inlet 22, a first set of tetrahedral channels 50 with open upstream ends and a second set of tetrahedral channels 52 intersecting the first set of tetrahedral channels 50 and having closed upstream ends are defined by a first set of wall segments 46 that are alternately sealed to each other at the adhesive 48. At the downstream outlet 24, a third set of tetrahedral channels 58 with closed downstream ends and a fourth set of tetrahedral channels 60 intersecting the third set of tetrahedral channels 58 and having open downstream ends are defined by a second set of wall segments 54 that are alternately sealed to each other at the adhesive 56. The first set of bends 30 includes a first sub-set of bends 62 defining the first set of tetrahedral channels 50 and a second sub-set of bends 64 defining the second set of tetrahedral channels 52. The second sub-set of bends 64 gradually decreases in the transverse direction 40 as they extend axially from the upstream inlet 22 toward the downstream outlet 24. The second set of bends 32 includes a third sub-set of bends 66 defining a third set of tetrahedral channels 58 and a fourth sub-set of bends 68 defining a fourth set of tetrahedral channels 60. The fourth sub-set of bends 68 tapers in the transverse direction 40 as they extend axially from the downstream outlet 24 toward the upstream inlet 22.

[0114] The first group of tetrahedral channels 50 and the second group of tetrahedral channels 52 (see...) Figures 4-8 This is opposite to the third group of tetrahedral channels 58 and the fourth group of tetrahedral channels 60. Each tetrahedral channel 50, 52, 58, 60 is elongated in the axial direction 28. Each tetrahedral channel has a cross-sectional area along a cross-sectional plane defined by direction 40 and lateral direction 44. As the first group of tetrahedral channels 50 and the second group of tetrahedral channels 52 extend along the axial direction 28 from the upstream inlet to the downstream outlet 24, the cross-sectional area of ​​the first group of tetrahedral channels 50 and the second group of tetrahedral channels 52 decreases. As the third group of tetrahedral channels 58 and the fourth group of tetrahedral channels 60 extend along the axial direction 28 from the downstream outlet 24 to the upstream inlet, the cross-sectional area of ​​the third group of tetrahedral channels 58 and the fourth group of tetrahedral channels 60 decreases. In one embodiment, the bend line 26 bends at a sharp angle, see Figure 3 As shown in 80. In other embodiments, the bend line is rounded along a given radius, see... Figure 3 The 82 is shown by the dashed line.

[0115] The filter medium 20 is also provided with a generally flat sheet 84 extending laterally across the bend line. In one embodiment, the sheet is formed of a filter medium material, which may be the same filter medium material as the pleated filter element including the wall section 34. The sheet 84 extends axially along the entire axial length of the axial direction 28 between the upstream inlet and the downstream outlet 24, and laterally along the entire lateral width of the lateral direction 44, sealing the passage to prevent dirty upstream air from bypassing to clean downstream air without passing through and being filtered by the wall section 34. In one embodiment, the sheet 84 is planar rectangular along the plane defined by the axial direction 28 and the lateral direction 44. In another embodiment, the sheet 84 is slightly corrugated, see Figure 6 The dashed line at position 86 indicates this. In one embodiment, sheet 84 is wound together with filter media 20 into a closed loop to form a filter media package, and in various embodiments, the closed loop has a shape selected from the group consisting of: Figure 9 Circular (filter media package 112a) Figure 10 The shapes include racetrack-shaped (filter media package 112b), elliptical, oblong, and other closed-loop shapes. In other embodiments, multiple pleated filter media layers 20 and sheets are stacked on top of each other in a stacked panel arrangement (see...). Figures 11-13 (Filter media package 112c)) to form a rectangular filter media package. Spacers or protrusions such as 88 may be used as needed for spacing and support between stacked elements.

[0116] like Figure 9 As shown, the circularly shaped wound filter medium 20 has a distance OC substantially equal to the distance between the inner cross-section of the housing 101 and the outer cross-section of the housing 101. For example, in embodiments where the filter medium 20 has two or more cross-sections of different sizes, each cross-section is substantially equal to the corresponding inner cross-section of the housing 101. Figure 10 The racetrack-shaped filter medium 20 has a first outer cross-sectional distance OC1 along its long axis and a second outer cross-sectional distance OC2 along its short axis, each of the first outer cross-sectional distance OC1 and the second outer cross-sectional distance OC2 being substantially equal to the corresponding inner cross-sectional distance of the housing 101.

[0117] Figures 14-16 Another embodiment with piece 84 removed is shown, and it is similar to... Figures 6-8 And similar figure labels as above are used in appropriate places for ease of understanding. Figures 14-16The filter element has an upstream inlet 22 for receiving incoming dirty fluid and a downstream outlet 24 for discharging clean, filtered fluid. As described above, wall segments are alternately sealed to each other at the upstream inlet 22 (e.g., at 48 by an adhesive or a section of filter media) to define a first set of channels 50 with open upstream ends and a second set of channels 52 intersecting the first set of channels and having closed upstream ends. Wall segments are alternately sealed to each other at the downstream outlet 24 (e.g., at 56 by an adhesive or a section of filter media) to define a third set of channels 58 with closed downstream ends and a fourth set of channels 60 with open downstream ends. Bends include a first sub-group bend 62 defining the first set of channels 50, a second sub-group bend 64 defining the second set of channels 52, a third sub-group bend 66 defining the third set of channels 58, and a fourth sub-group bend 68 defining the fourth set of channels 60.

[0118] The elongated tetrahedral channels allow cross-flow between adjacent channels. In implementations of air filters, this cross-flow results in a more uniform dust load on the upstream side of the medium. In one embodiment, the shape of the elongated tetrahedral channels is intentionally configured to allow an upstream void volume larger than the downstream void volume to increase filter capacity. Various fluids can be filtered, including air, air / fuel mixtures, or other gases, and liquids such as fuels, lubricants, or water.

[0119] Figure 17A This is a schematic diagram of a filter assembly 200 according to another embodiment. The filter assembly 200 can be used to filter gases (e.g., air) or another fluid supplied to an engine. The filter assembly 200 includes a filter housing 201 and a filter element 210. In some embodiments, the filter element 210 may be a disposable in-line filter including the filter housing 201. In other embodiments, the filter element 210 may include a cylindrical filter element that can be mounted in the filter housing 201.

[0120] A filter housing 201 (e.g., a shell or container) defines an internal volume having an internal cross-section defining an internal cross-sectional distance IC, within which a filter element 210 is positioned. The filter housing 201 includes a base 203 and sidewalls 202 projecting perpendicularly from the outer edge of the base 203. The filter housing 201 may be substantially similar to the filter housing 101.

[0121] A cap 204 or cover is coupled to the end of the filter housing 201 remote from the base 203. The cap 204 may be removably coupled to the sidewall 202, for example via a threaded, snap-fit ​​mechanism, friction fit, clamp, screw, nut, or any other suitable coupling mechanism. In some embodiments, one or more inlets 206 may be defined in the cap 204 to allow unfiltered fluid to enter the internal volume of the filter housing 201. In other embodiments, the inlets 206 may be defined in the sidewall 202, near the cap 204. Additionally, an outlet 208 may also be defined in the cap 204. The cap 204 is removably coupled to the filter housing 201 to allow the filter element 210 to be inserted into and / or removed from the internal volume of the filter housing 201. In other embodiments, the cap 204 may be permanently fixed to the filter housing 201 such that the filter element 210 cannot be removed from the filter housing 201 without physical damage to the filter housing 201. The cap 204 can be formed of any suitable material (e.g., metal, plastic, polymer, elastomer, rubber, reinforced rubber, etc.). In some embodiments, the filter element 210 can be configured to be coupled to a filter head (e.g., screwed onto a filter head). In such embodiments, the cap 204 can be removed.

[0122] Filter element 210 is located within the internal volume along the longitudinal axis A of filter assembly 200. L Positioning. Filter element 210 includes an axial flow filter media package 212, the axial flow filter media package 212 having a longitudinal axis A. L The medium passes through a channel 219 defined by the axial flow filter media package. The end of channel 219 opposite to base 203 is coupled to outlet 208. In some embodiments, a central tube 218 may be disposed in channel 219. The central tube 218 may comprise a solid central tube (i.e., without any perforations or openings). The end of the central tube 218 is coupled to outlet 208.

[0123] A first support structure 214 is coupled to a first longitudinal end of the filter medium 212 away from the base 203, while a second support structure 216 is coupled to a second longitudinal end of the filter medium opposite to the first longitudinal end. Support structures 214, 216 may be substantially similar to support structures 114, 116. In some embodiments, the first support structure 214 and the second support structure 216 may include a grid or mesh. A sealing member 230 (e.g., an O-ring or gasket) may be disposed between the first support structure 214 and the sidewall 202 to prevent contaminated fluid from flowing around the filter medium package 212, as described above with respect to sealing member 130. Although shown as including two support structures 214, 216, in other embodiments, the filter element 210 may have a single support structure coupled to a longitudinal end of the filter medium package 212 (where the fluid exits the filter medium package 212 after passing through it), for example, a longitudinal end near the base 203.

[0124] As previously described, cap 204 is coupled to the end of housing 201 opposite to base 203, such that inlet chamber 207 is defined between first support structure 214 and cap 204. Base 203 is located at a lower height relative to cap 204. Cap 204 may define outlet 208 and one or more inlets 206 allowing fluid to enter inlet chamber 207. Outlet 208 is fluid-sealed to inlet chamber 207, for example, via central tube 218.

[0125] The axial flow filter media package 212 is configured to allow fluid to flow along the longitudinal axis A L The fluid flows through and is filtered in a first direction (e.g., from cap 204 toward base 203). A flow reversal chamber 209 is defined between the second support structure 216 and the base 203. The filtered fluid changes direction in the flow reversal chamber 209 and flows toward outlet 208 through channel 219 (e.g., within central tube 218), and is discharged from housing 201 via outlet 208. Therefore, filter assembly 200 is a reverse flow filter assembly.

[0126] Because the flow reversal chamber 209 is located at a lower height relative to the inlet chamber 207, liquids (e.g., water, oil droplets, etc.) can accumulate in the flow reversal chamber 209. A discharge port 211 can be provided in the flow reversal chamber 209 (e.g., defined in the base 203, or defined in the sidewall 202, near the base 203) to allow the discharge of liquids (e.g., water) collected in the flow reversal chamber 209. A discharge plug (not shown) can be removably coupled to the discharge port 211 and used to plug the discharge port 211. If the level of the liquid (e.g., water) collected in the flow reversal chamber 209 rises above a predetermined level (e.g., determined by a level sensor), the discharge plug can be removed to discharge the liquid from the flow reversal chamber 209.

[0127] The axial flow filter media pack 212 includes a porous material having a predetermined pore size and configured to filter particulate matter from a fluid flowing through it, thereby producing a filtered fluid. In some embodiments, the axial flow filter media pack 212 may include a tetrahedral filter media pack, which may include pleats, for example, regarding... Figures 2-16 Any tetrahedral filter media described. In other embodiments, the axial flow filter media package 212 may include a grooved media package, an origami-style media package, a straw-style media package, or any other suitable filter media package.

[0128] The axial flow filter media package 212 can have any suitable cross-sectional shape corresponding to the cross-sectional shape of the housing 201. In some embodiments, the axial flow filter media package 212 can have a circular cross-section. For example, the axial flow filter media package 212 may include axial flow filter media packages 112a, 112b, which are wound into the shape shown below. Figure 17B The circular shape shown (filter media package 112a) or as shown Figure 17B The racetrack-shaped design shown (filter media package 112b). Although Figure 17B and Figure 17C The axial flow filter media packages 112a and 112b are respectively substantially similar to those made of... Figure 9 112a and Figure 10 The filter media package formed by 112b is different from it in that channel 19 is defined to pass through Figure 17B-17C The filter media packages 112a and 112b are designed to allow the filtered fluid to flow in the opposite direction to the outlet 208. Therefore, Figure 17BThe outer cross-sectional distance OC of the filter media package 112a includes the sum of the following: (a) the cross-sectional distance (e.g., diameter) of the channel 19; (b) a first radial distance R1 from the inner surface of the filter media package 112a forming the channel at the first position to the outer surface of the filter media package 112a near the first position; and (c) a second radial distance R2 from the inner surface of the filter media package 112a at the second position opposite to the first position to the outer surface of the filter media package 112a near the second position.

[0129] At least a portion of the filter media package 212 has an outer cross-sectional distance OC (e.g., diameter or width) that is substantially equal to the inner cross-sectional distance IC (e.g., diameter or width) of the internal volume of the housing 201. For example, the filter media package 212 may be a cylindrical filter media or a wound filter media, at least a portion of which has an outer diameter equal to or greater than 98% of the inner diameter of the filter housing 201. In some embodiments, the distance D between the inner surface of the sidewall 202 and the radial outer surface of the filter media package 212 may range from 0.1 mm to 5 mm. In embodiments where the filter media package 212 has various unequal cross-sections, each cross-section of the filter media package 212 may be substantially equal to the corresponding cross-section of the filter housing 201. It should be understood that, although Figure 17A The filter media package 212 is shown to have a constant outer cross-section, but in other embodiments, the filter media package 212 may have a variable cross-section (e.g., a tapered cross-section).

[0130] The outer cross-sectional distance OC of at least a portion of the filter media package 212 is substantially equal to the inner cross-sectional distance IC of the filter housing 201. This allows the radially outer surface of the filter media package 212 to be sufficiently close to the inner surface of the sidewall 202 to provide at least a partial seal and, to some extent, structural support. Furthermore, this allows for more efficient use of the housing's internal volume, providing an increased filter media area for increased capacity, reducing surface velocity and pressure drop, and thus increasing the overall filtration efficiency of the filter assembly 200.

[0131] Figure 18 This is a side cross-sectional view of the filter element 210 according to a specific embodiment. The filter media package 212 of the filter element 210 includes a plurality of filter media layers 213. Inlet sealing members 215 (e.g., polymer seals or adhesives) are disposed between the spaced-apart filter media layers 213, close to the first support structure 214, to prevent flow into the outlet channels 223 formed between the corresponding filter media layers 213. Furthermore, inlet channels 221 are formed between the filter media layers 213 and between the inlet sealing members 215. Contaminated fluid flows through the first support structure 214 and enters the inlet channels 221.

[0132] The outlet sealing member 217 is positioned between the spaced-apart filter media layers 213, near the second support structure 216 opposite the inlet of the inlet channel 221, and blocks flow out of the inlet channel 221. The flow outlet channel 223 is defined between the filter media layers 213 opposite to the inlet sealing member 215. When fluid enters the inlet channel 221, it is forced to flow from the inlet channel 221 through the filter media layers 213 into the outlet channel 223, and forward into the flow reversal chamber 209. As the fluid flows through the filter media layers 213, contaminants are trapped within them, and the filtered fluid flows out of the outlet channel 223.

[0133] Figure 19 This is a schematic diagram of a filter assembly 300 according to another embodiment. The filter assembly 300 can be used to filter gas (e.g., air) or another fluid supplied to an engine. The filter assembly 300 includes a filter housing 301 and a filter element 310, which may be substantially similar to filter housing 201 and filter element 210, respectively.

[0134] A filter housing 301 defines an internal volume having an inner cross-section IC, within which a filter element 310 is positioned. The filter housing 301 includes a base 303 and a sidewall 302 projecting perpendicularly from the outer edge of the base 303. The filter element 310 includes an axial flow filter media package 312 defining a channel 319 therebetween. The axial flow filter media package 312 is configured to allow fluid to flow along its longitudinal axis A. L The fluid flows through and is filtered in a first direction. A first support structure 314 (e.g., a grid or mesh) is coupled to a first end of the axial flow filter media package 312 near the base 303, while a second support structure 316 (e.g., a grid or mesh) is coupled to a second end of the axial flow filter media package 312 opposite the first end. In some embodiments, a central tube 318 (e.g., a non-porous central tube) may be positioned in a channel 319. Although shown as including two support structures 314, 316, in other embodiments, the filter element 310 may have a single support structure coupled to a longitudinal end of the filter media package 312 (where the fluid exits the filter media package 312 after passing through it), for example, a longitudinal end near the base 303.

[0135] A cap 304 or cover is coupled to the end of the filter housing 301 opposite the base 303, such that an inlet chamber 307 is defined between the second support structure 316 and the cap 304. The cap 304 may be removably coupled to the sidewall 302, for example via a threaded, snap-fit ​​mechanism, friction fit, clamp, screw, nut, or any other suitable removable coupling mechanism. In some embodiments, one or more inlets 306 may be defined in the cap 304 to allow unfiltered fluid to enter the internal volume of the filter housing 301. In other embodiments, inlets 306 may be defined in the sidewall 302, adjacent to the cap 304. Furthermore, an outlet 308 may also be defined in the cap 304. The outlet 308 is sealed to the inlet chamber 307, for example, via a central tube 318. The cap 304 is removably coupled to the filter housing 301 to allow the filter element 310 to be inserted into and / or removed from the internal volume of the filter housing 301. In other embodiments, the cap 304 may be permanently attached to the filter housing 301 such that the filter element 310 cannot be removed from the filter housing 301 without physical damage to it. The cap 304 may be formed of any suitable material (e.g., metal, plastic, polymer, elastomer, rubber, reinforced rubber, etc.). In some embodiments, the filter element 310 may be configured to be coupled to a filter head (e.g., screwed onto a filter head). In such embodiments, the cap 304 may be removed.

[0136] Unlike filter assembly 200, cap 304 is located at a lower height relative to base 303. Inlet 306, defined by cap 304, allows fluid to enter inlet chamber 307 located at the lower height. Flow reversal chamber 309 is defined between first support structure 314 and base 303. Filtered fluid changes its flow direction from a first direction to a second direction opposite to the first direction in flow reversal chamber 309 and flows through channel 319 to outlet 308. Sealing member 330 (e.g., O-ring or gasket) may be disposed between second support structure 316 and sidewall 302 to prevent contaminated fluid flow from bypassing filter media 312, as described above with respect to sealing members 130, 230.

[0137] Because the inlet chamber 307 is located at a lower height relative to the flow reversal chamber 309, liquids (e.g., water, oil droplets, etc.) can accumulate in the inlet chamber 307. A drain port 311 may be provided in the inlet chamber 307 (e.g., defined in the cap 304, or defined in the sidewall 302, near the cap 304) to allow the discharge of liquids (e.g., water) collected in the inlet chamber 307. A drain plug (not shown) may be removably coupled to the drain port 311 and used to plug the drain port 311. If the level of the liquid (e.g., water) collected in the inlet chamber 307 rises above a predetermined level (e.g., determined by a level sensor), the drain plug can be removed to discharge the liquid from the inlet chamber 307.

[0138] Figure 20 This is a side cross-sectional view of the filter element 310 according to a specific embodiment. The filter media package 312 of the filter element 310 includes a plurality of filter media layers 313, as described with respect to the filter element 310. Inlet sealing members 315 (e.g., polymer seals or adhesives) are disposed between the spaced-apart filter media layers 313, near the second support structure 316, to prevent flow into the outlet channels 323 formed between the respective filter media layers 313. Furthermore, inlet channels 321 are formed between the filter media layers 313 between the inlet sealing members 315. Contaminated fluid enters the inlet 306a defined in the central tube 318 (the central tube 318 is disposed in the central channel defined by the filter media package 312), undergoes a change of direction in the flow reversal chamber 309a defined between the base 304a of the filter housing (e.g., filter housing 301) where the filter element 310 is disposed and the filter element 310, and flows through the first support structure 314 and into the inlet channel 321.

[0139] An outlet sealing member 317 is positioned between the spaced-apart filter media layers 313, near a first support structure 314 opposite the inlet end of the inlet passage 321, and blocks flow out of the inlet passage 321. An outlet passage 323 is defined between the filter media layers 313 opposite the inlet sealing member 315. When fluid enters the inlet passage 321, it is forced to flow from the inlet passage 321 through the filter media layers 313 into the outlet passage 323 and forward into the flow reversal chamber 309. As the fluid flows through the filter media layers 313, contaminants are trapped within them, and the filtered fluid flows out of the outlet passage 323 into the flow reversal chamber 309.

[0140] In various embodiments, any filter assembly described herein may include a wall-flow filter media package, a flow-through filter media package, or any other suitable filter media package. For example, Figure 21An exemplary filter media layer 520 is shown, which has a plurality of variable-shape corrugated folds 522, similar to or equivalent to the... Figure 4 The filter medium 20 is described.

[0141] In some embodiments, any filter media described herein may comprise layers of filter media folded along its axis, such that channels or pouches are formed between the folds of the filter media. The filter media may be rolled up or wound to form a wound filter media package. Such filter media may allow fluid to flow into the filter pouches without the use of media corrugations. Such filter media may also include inflow and / or outflow meshes designed to allow fluid to flow out of cavities between concentric layers of media pouches.

[0142] For example, Figure 22 This is a top perspective view of a wound filter media package 612 according to an embodiment, a portion of which is unfolded to show the various layers included. The filter media package 612 includes a filter media layer 613 folded along a folding axis 615 such that a first edge of the filter media layer 613 is close to an opposite edge after folding, and a filter channel or filter bag-like portion 623 is formed by the filter media layer 613, i.e., by the space formed between the folded portions of the filter media layer 613. The filter media package 612 includes a cylindrical roll of the filter media layer 613 wound along its folding axis 615. In other words, the folding axis 615 is oriented perpendicular to the longitudinal axis of the filter media package 612, but the direction of rotation is along the folding axis 615.

[0143] The filter bag 623 is configured to receive unfiltered fluid. Unfiltered fluid enters the filter bag 623 and flows through the filter media layer 613, which traps contaminants or particles, and clean fluid flows out of the filter media bag 612. In some embodiments, the filter media layer 613 comprises a single thin layer, for example, having a thickness of less than 1 mm. A thin filter media layer 613 can provide the same or better performance as a thicker filter media layer, thereby allowing more filter media layers 613 to be packed into a smaller space. The filter media layer 613 comprises fully synthetic nanofibers formed from synthetic fibers, cellulose, glass fibers, polymers (e.g., polyester), any other suitable materials, or combinations thereof. In some embodiments, a backing sheet (e.g., a loosely woven fabric layer or a thin layer of fully synthetic material) may be attached to, for example, laminated onto the filter media layer 613.

[0144] An inflow mesh 642 can be disposed within the filter bag portion 623. The inflow mesh 642 can be formed of a polymeric or metallic material and is designed to minimize confinement caused by the axial flow of fluid, for example, by maintaining flow space between the folds of the filter media layer 613. In some embodiments, such as Figure 22 As shown, the inflow mesh 642 can float freely within the filter bag portion 623. In other embodiments, the inflow mesh 642 can be glued or acoustically welded to the filter bag portion 623. For example, Figure 23 A filter medium 612 is shown, wherein the filter medium layer is bonded to itself and / or the inflow mesh at a joint 648 formed along the fold axis 615. The joint 648 may be formed by adhesive or acoustic welding.

[0145] In some embodiments, the filter media package 612 further includes an outflow mesh 644 disposed on the surface of the filter media layer outside the filter bag portion 623. The outflow mesh 644 may also be formed of a polymeric or metallic material and is configured to minimize axial fluid flow in the outlet channels formed between the outer surfaces of the filter bag portion 623 when the filter bag portion 623 is rolled up to form the wound filter media package 612. The outflow mesh 644 may also serve as a support structure to prevent the wound filter media package 612 from stretching, for example, by providing a high-friction material in the cavities or flow channels formed between the concentric filter bag portions 623. In some embodiments, the outflow mesh 644 may be secured to the filter media layer 613 via a layer or strip of sealant 646 (e.g., adhesive) arranged parallel to and away from the folding axis 615 of the filter media layer 613.

[0146] The inflow mesh 642 and the outflow mesh 644 can have different geometries and / or thicknesses. For example, the inflow mesh 642 can have a first thickness, and the outflow mesh 644 can have a second thickness less than the first thickness. The thicker inflow mesh 642 allows fluid and particles to flow freely within the filter bag portion 623, while the thinner outflow mesh 644 is sufficient to accommodate the filtered fluid flowing through and out of the outlet flow channels formed between the rolls of filter media pack 612. Different thicknesses can provide the benefit of reduced spacing, thereby allowing more rolls of filter media layer 613 to be packed in the same volume. In some embodiments, the inflow mesh 642 and the outflow mesh 644 can have thicknesses in the range of 0.5 mm to 1.0 mm.

[0147] Figures 24-28 This is a schematic diagram illustrating various operations in which the filter media bag-shaped portion 623 is formed from the filter media layer 613. At operation 1 (see...) Figure 24This defines the fold axis 615 of the filter media layer 613 and positions the inflow mesh 642 on the portion of the filter media layer 613 located on one side of the fold axis 615. At operation 2 (see...) Figure 25 The filter media layer 613 is folded along the folding axis 615, so that the filter bag-shaped portion 623 is formed between the folded portions of the filter media layer 613, and the inflow mesh 642 is inserted between the folded portions of the filter media layer 613, so that the inflow mesh 642 is positioned inside the filter media bag-shaped portion 623.

[0148] In some embodiments, at operation 3 (see Figure 26 A joint 648 (e.g., acoustic weld or thermal weld) can be formed along the fold axis 615 of the filter media layer 613. In other embodiments, a sealant (e.g., an adhesive strip) can be applied along the fold edge. The weld 648 or sealant bonds the filter media layer 613 to itself and / or to the inflow mesh 642 along the fold axis 615. For example, the folded portions of the filter media layer 613 can be acoustically or thermally bonded at the joint 648 to form a filter bag 623 by directly welding the folded portions of the filter media layer 613 together to form the filter bag 623, as shown. Figure 26 As shown in the diagram. The inflow mesh 642 can be inserted into the filter bag portion 623 later in the production process. In other embodiments, the inflow mesh 642 can be directly acoustically or thermally bonded between the folds of the filter media layer 613, such that the bottom joint 648 includes the inflow mesh 642 inserted between the folds of the filter media layer 613 at the fold axis 615. In some embodiments, when using a non-weldable inflow mesh material, weldable fibers can be provided near the fold axis to help seal the bottom of the filter bag portion 623 near the fold axis 615.

[0149] exist Figure 27In other embodiments shown, operation 3 may include forming a first joint 652 (e.g., an acoustic weld or thermal weld) near the folding axis 615 to attach a backing sheet (e.g., a loosely woven fabric or laminate) disposed on the surface of the filter media layer 613 to the inside or outside of the filter bag-like portion 623. A second joint 654 (e.g., an acoustic weld or thermal weld) is formed along the folding axis 615 adjacent to the first acoustic weld 652 to join the folded portions of the filter media layer 613 and form the filter bag-like portion 623. This configuration prevents the backing sheet from peeling off from the filter media layer 613 at the stressed bottom edge of the filter media located at the folding axis 615. The inflow mesh 642 may be disposed in the filter bag-like portion 623 after the joints 652, 654 are formed, or may be attached between the folded portions of the filter media layer 613, as previously described herein.

[0150] In some embodiments, at operation 4 (see Figure 28 A third acoustic weld 656 and a fourth acoustic weld 658 can be formed along the edge of the folded portion of the filter media layer 613 perpendicular to the fold axis 615. This allows fluid to flow into the filter bag 623 only at the axial inlet of the filter bag 623 and prevents fluid leakage from the edge perpendicular to the fold axis.

[0151] Figure 29 This is a side cross-sectional view of a filter element 610a according to one embodiment. The filter element 610a includes a wound filter medium 612, which includes a filter medium layer 613 wound into a roll. A first support structure 614 (e.g., a grid or mesh) is coupled to a first end of the filter medium package 612 opposite to the fold axis 615 of the filter medium layer 613, while a second support structure 616 (e.g., a grid or mesh) is coupled to a second end of the filter medium package 612 opposite to the first end. Figure 30 This is a side cross-sectional view of filter element 610b, which is substantially similar to filter element 610a and includes similar components, except that an acoustic weld 648 is formed along the fold axis 615 of filter media layer 613, as previously described herein.

[0152] Channel 619 is defined by the longitudinal axis of filter media package 612. A central tube (e.g., central tubes 218, 318) may be disposed in channel 619. Channel 619 allows filter elements 610a, 610b to operate in a reverse flow mode, as previously described with respect to filter elements 210, 310. In such an embodiment, after axially passing through filter media package 612, the fluid is recirculated in a flow reversal chamber 609 formed between the base 603 of the second support structure 616 and the housing 601 (in which filter elements 610a, 610b are disposed). In other embodiments, unfiltered fluid may first enter channel 619 and then change its flow direction to enter filter media package 612. In yet another embodiment, channel 619 may be removed, such that filter elements 610a, 610b are configured to provide axial flow filtration, as previously described with respect to filter element 110.

[0153] like Figures 29-30 As shown, filter bag-shaped portions 623 are formed between the folded portions of the filter media layer 613, and an inflow mesh 642 is disposed within the filter bag-shaped portions 623. An outflow mesh 644 is disposed between adjacent filter bag-shaped portions 623. A sealant 646 (e.g., a polymer sealant or adhesive) is disposed near the first support structure 614 between the filter bag-shaped portions 623 to prevent fluid from flowing into the outlet channel formed between adjacent filter bag-shaped portions 623. Unfiltered fluid flows axially into the filter bag-shaped portions through the first support structure 614. The fluid then passes through the filter media layer 613 and is filtered. The filtered fluid then flows axially outward through the outlet channel into the flow reversal chamber 609 and outflows from the filter element through channel 619. In some embodiments, the filter media pack 612 may be used in a filter assembly configured for inline flow without flow reversal.

[0154] Upstream filter media 660 may be disposed upstream of filter elements 610a, 610b. Upstream filter media 660 may include a coarse filter media layer with a pore size larger than that of filter media package 612. Upstream filter media package 612 is configured to filter out large particles that may obstruct fluid flow into filter bag portion 623. In some embodiments, upstream filter media 660 may include, but is not limited to, woven or non-woven mesh, synthetic filter media, cellulose filter media, or a gradient pore size filter media layer constituting a composite material. Although Figures 29-30The illustration shows the upstream filter medium 660 being coupled to the first support structure 614; however, in other embodiments, the upstream filter medium 660 may be located at any suitable location upstream of the filter elements 610a, 610b. In other embodiments, the upstream filter medium 660 may include a disc of filter media, an axial flow filter stage connected in series with the filter element 610, the axial flow filter stage being disposed in the filter housing 601 or in a separate filter housing upstream of the filter housing 601.

[0155] The wound filter media pack 612 offers several advantages, including, for example, increasing the media packing density (i.e., filter media surface area) within the same filter volume by packing the filter media layer 613 into a dense roll and providing filter bag-like portions 623 therein, while preventing increased flow restriction through the use of inflow and outflow meshes 642 and 644. Increasing the packing density of the filter media pack 612 within the same filter volume increases its capacity and reduces maintenance cycles, thereby lowering maintenance costs. The wound filter media pack 612 also reduces the surface velocity of the fluid, which can improve the removal of contaminants from the fluid.

[0156] The outer winding layer of any wound filter element (e.g., filter elements 610a, 610b) tends to bulge outwards if not properly restrained. This bulging creates stress concentration points where the filter media (e.g., filter media package 612) may fail. Restraining this bulging can extend the lifespan of the wound filter element. Bulging can be restrained by a polymeric or metallic, woven, non-woven, or extruded mesh or media basket surrounding the entire outflow side of the filter media. Alternatively, a polymeric or metallic, woven, non-woven, or extruded mesh or layer can be used as an outer winding or tape wrapped around the filter media. In some embodiments, the outer winding may be disposed only on the outermost wall of the filter media on the outflow side (excluding the bottom end of the filter media). In specific embodiments, bulging can be limited by providing a housing with an inner cross-section such that the outer cross-sectional distance (e.g., diameter, width, etc.) of the filter medium is substantially equal to the inner cross-sectional distance (e.g., diameter, width, etc.) of the housing, for example, as described above with respect to filter elements 110, 210, 310. In such embodiments, the sidewalls (e.g., sidewalls 102, 202, 302) of the housing (e.g., housings 101, 201, 301) limit the bulging of the filter medium contained therein.

[0157] In some embodiments, protrusions or ribs may be used to limit the bulging of the wound filter media. For example, Figure 31This is a perspective view of a filter element 710 according to one embodiment. The filter element 710 includes a wound filter media package 712 (e.g., any wound filter media described herein). A support structure 714 (e.g., a grid, mesh, or end plate) is coupled to a longitudinal end of the filter media package 712. Ribs or protrusions 762 extend axially from the edge of the support structure 714 along the outer surface of the filter media at least partially toward the opposite longitudinal end of the filter media package 712. The ribs 762 may be formed of a sufficiently robust material (e.g., a polymer such as polyurethane) that can resist bulging of the filter media package 712. In some embodiments, the ribs 762 may bend around the opposite ends of the filter media package 712 and extend to the bottom surface of the filter media package 712 located at the opposite longitudinal ends. In such embodiments, the ribs 762 may serve as a bottom end plate and prevent the filter media package 712 from expanding or contracting (which may occur under high fluid pressure). In other embodiments, one or more ribs may be arranged circumferentially around the filter media package 712.

[0158] In some embodiments, bulging can be prevented by forming point joints at different locations on the filter media package. For example, Figure 32 A partially unfolded roll-up filter media package 812 is shown. The roll-up filter media package 812 includes a filter media layer 613 folded along a folding axis 615 to form a filter bag-like portion 623. The roll-up filter media package 812 has an inflow mesh 642 disposed within the filter bag-like portion 623, as previously described herein. Multiple point joints 848 (e.g., acoustic welds or thermal welds) are formed at different locations on the outer surface of the filter media layer 613 through the outermost roll of the filter bag-like portion 623 of the filter media package 612. Figure 33 A perspective view of a wound filter media package 812 is shown, illustrating a plurality of point joints 848 formed on the outer surface of the wound filter media package 812. The plurality of point joints 848 can reduce stress on the outermost roll of the filter media package 812 without the need for external components to prevent bulging.

[0159] In some embodiments, the inflow and / or outflow meshes may have a thickness that varies continuously from one longitudinal end of the filter media to the opposite longitudinal end. For example, Figure 34This is a cross-section of a portion of a filter media package 912 according to one embodiment. The filter media package 912 includes a filter media layer 613 folded to define a filter bag-shaped portion 623. An inflow mesh 942 is disposed in the filter bag-shaped portion 623, and an outflow mesh 944 is disposed between adjacent filter bag-shaped portions 623. The inflow mesh 942 has a continuously varying thickness that decreases from the inlet end of the filter media package 912 (through which fluid enters the filter media package 912) toward the opposite outlet end of the filter media package 912. The greater thickness near the inlet end reduces the back pressure of the fluid entering the filter bag-shaped portion 623, and the decreasing thickness in the opposite direction causes a proportional increase in the fluid back pressure, prompting fluid to flow through the filter media layer 613.

[0160] Conversely, the outflow mesh 944 has a continuously varying thickness that increases from the inlet end of the filter media pack 912 toward the outlet end. This increasing thickness toward the outlet end provides a lower back pressure for the fluid flowing toward the narrower outlet end of the filter media pack 912. This facilitates fluid flow through the filter media layer 613 from the filter bag 623 to the outlet channel therebetween.

[0161] In some embodiments, the formed plurality of filter bag-like portions of different lengths may be stacked or layered on top of each other to form a filter medium with a desired shape. For example, Figure 35 This is a top cross-sectional view of the filter media package 1012. The filter media package 1012 includes a plurality of filter bag-shaped portions 623 forming the filter media package 1012, as previously described herein. Each of the plurality of filter bag-shaped portions 623 is physically separated from the adjacent filter bag-shaped portion 623. An inflow mesh 642 is positioned within each filter bag-shaped portion 623, and an outflow mesh 644 is disposed between each adjacent filter bag-shaped portion 623. The filter bag-shaped portions 623 have different lengths, with the outermost filter bag-shaped portion 623 having the smallest length, the filter bag-shaped portion 623 positioned along the central axis of the filter media package 1012 having the longest length, and the filter bag-shaped portion 623 disposed between the outermost filter bag-shaped portion 623 and the central filter bag-shaped portion 623 having a length that increases from the outside to the center, thereby giving the filter media package 1012 an elliptical cross-section. In other embodiments, layers of different lengths can be used to form filter media having any other shape (e.g., circular, oblong, racetrack-shaped, trapezoidal, square, rectangular, polygonal, semicircular, crescent-shaped, wedge-shaped, etc.).

[0162] Figure 36This is a top cross-sectional view of a filter media package 1112 according to another embodiment. The filter media package 1112 includes a filter media layer 613 defining a filter bag-like portion, as previously described herein. Unlike filter media package 1012, the filter bag-like portion 623 of the filter media package 1112 is folded multiple times along its width to form a stack. Each fold is made over a longer distance along the width of the filter bag-like portion 623 relative to a previous fold from the outermost fold to a fold positioned along the central axis of the filter media package 1112. The folding distance from the central axis to the opposite outer end then decreases with each subsequent fold. This results in the filter media package 1112 having, as Figure 36 The cross-section shown is elliptical. However, different fold lengths can be used to form filter media with any other shape (e.g., circular, oblong, racetrack-shaped, trapezoidal, square, rectangular, polygonal, semicircular, crescent-shaped, wedge-shaped, etc.).

[0163] The various embodiments of the wound filter element described herein can be implemented in any suitable configuration. In some embodiments, the wound filter element may be disposed within a housing (e.g., housings 101, 201, 301, 601), and the outer edge of the filter element may be sealed to the sidewall of the corresponding housing using a heat-melt or active sealant. In other embodiments where the wound filter element includes a removable cylindrical filter element, a top support structure or end plate may be sealed to the top end of the wound filter element. For example, the filter element may be sealed to the skirt of the top end plate via a heat-melt or active sealant. The top end plate is then sealed to the inner surface of the filter housing or cap (e.g., nut plate) using a radial sealing member (e.g., an O-ring or face seal gasket).

[0164] In some embodiments, the filter element assembly may include a plurality of axial-flow wound filter elements arranged in series. For example... Figure 37 This is a side cross-sectional view of a filter element assembly 1210 according to an embodiment. The filter element assembly 1210 includes a main filter element 1210a, which includes a main filter media package 1212a, as previously described herein. The main filter media package 1212a includes a wound axial flow filter media package. A first support structure 1214a (e.g., a grid, mesh, or perforated end plate) is coupled to the inlet end of the main filter media package 1212a. The radial edge 1230a of the first support structure 1214a may be configured to provide a radial seal with the inner sidewall of a housing in which the main filter media package 1212a is disposed, and the axial surface 1232a of the first support structure 1214a may be configured to provide an axial seal, for example, using a cap. The main filter element 1210a has a first width W1 and a first pore size to provide a first filtration efficiency.

[0165] The filter element assembly 1210 also includes a downstream filter element 1210b disposed downstream of the main filter element 1210a. The downstream filter element 1210b includes a downstream filter media package 1212b, which is also an axial flow filter media, but may, for example, define a channel 1219b therethrough to allow filtered fluid to flow backward through it. In such an embodiment, a corresponding channel may also be defined through the upstream filter media package 1212a. A second support structure 1214b is coupled between the main filter media package 1212a and the downstream filter media package 1212b to the top end of the downstream filter media package 1212b. A radial sealing member 1230b is disposed around the second support structure 1214b and configured to provide a fluid seal with a corresponding portion of the filter housing. The downstream filter media package 1212b may have a width W2 smaller than the first width W1 and may have a smaller pore size to provide a higher filtration efficiency than the main filter element 1210a.

[0166] Figure 38 This is a side cross-sectional view of a filter element assembly 1310 according to another embodiment. The filter element assembly 1310 includes a main filter element 1310a, which includes a main filter media package 1312a, as previously described herein. The main filter media package 1312a includes wound axial flow filter media. A first support structure 1314a (e.g., a grid, mesh, or perforated end plate) is coupled to the inlet end of the main filter media package 1312a. The main filter element 1310a has a first width W1, a first height H1, and a first pore size to provide a first filtration efficiency.

[0167] The filter element assembly 1310 also includes an upstream filter element 1310b disposed upstream of the main filter element 1310a and a downstream filter element 1310c disposed downstream of the main filter element 1310a. The upstream filter element 1310b includes an axial flow filter media package 1312b defining a channel 1319b therethrough, for example, to allow reverse flow through the channel 1319b. A second support structure 1314b (e.g., a grid, mesh, or perforated end plate) is coupled to the top end of the upstream filter media package 1312b and prevents expansion and contraction between the main filter element 1310a and the upstream filter element 1310b. A radial sealing member 1330b is disposed around the second support structure 1314b and configured to provide a radial seal against the sidewalls of the filter housing. The upstream filter element 1310b has a second width W2 greater than a first width W1 and a second height H2 less than a first height H1. In addition, the upstream filter element 1310b has a second pore size that can be larger than the first pore size of the main filter element 1310a.

[0168] The filter element assembly 1310 also includes a downstream filter element 1310c disposed downstream of the main filter element 1310a. The downstream filter element 1310c includes a downstream filter media package 1312c, which also includes axial flow filter media but defines a channel 1319c therethrough, for example to allow filtered fluid to flow in reverse through it. A third support structure 1314c (e.g., a grille, mesh, or perforated end plate) is coupled between the main filter media package 1312a and the downstream filter media package 1312c to the top end of the downstream filter media package 1312c and can prevent expansion and contraction. A fourth support structure 1316c (e.g., a grille, mesh, or perforated end plate) is coupled to the bottom end of the downstream filter media package 1312c opposite the top end. A radial sealing member 1330c is disposed around the fourth support structure 1316c and is configured to provide a fluid seal with a corresponding portion of the filter housing. The downstream filter media package 1312c may have a width W3 smaller than the first width W1 and a third pore size smaller than the first pore size in order to provide a higher filtration efficiency than the main filter media 1310a. While in some embodiments the upstream filter element 1310b and the downstream filter element 1310c may be configured to allow reverse flow, in other embodiments all filter elements 1310a, 1310b, and 1310c may be configured for reverse flow, or only one of the main filter element 1310a, upstream filter element 1310b, and / or downstream filter element 1310c may be configured to provide reverse flow, for example, to accommodate the architecture of a filter assembly that includes filter element 1310, or based on water treatment within the filter assembly.

[0169] Therefore, the filter element assembly 1310 can provide progressively higher filtration efficiency. For example, in some embodiments, the upstream filter media pack 1312b has a pore size of approximately 12 micrometers, the main filter media pack 1312a may have a pore size of approximately 5 micrometers, and the downstream filter media pack 1312c may have a pore size of approximately 3 micrometers. In other embodiments, the upstream filter media pack 1312b has a pore size of approximately 5 micrometers, the main filter media pack 1312a may have a pore size of approximately 2 micrometers, and the downstream filter media pack 1312c may have a pore size of approximately 3 micrometers.

[0170] In some embodiments, the filter assembly may include a first filter radially positioned within a channel defined in a second filter, such that the second filter at least partially surrounds the first filter. For example, Figure 39 This is a side cross-sectional view of a filter element assembly 1410 according to an embodiment. The filter element assembly 1410 includes an external filter media package 1412a that defines a first channel 1419a along its longitudinal axis. In some embodiments, a first central tube 1418a may be positioned within the first channel 1419a. The external filter media package 1412a may include folded filter media, such as filter media package 612, and may include wound filter media as previously described herein. A first support structure 1414a is coupled to the inlet end of the filter media package 1412a and may include a grid or mesh. The external filter media is positioned within a housing 1401. A flow reversal chamber 1409 is formed between the base of the housing 1401 and a second end of the external filter media package 1412a opposite to the first end. A radial seal (e.g., an O-ring or gasket) is positioned around the first support structure and forms a fluid-tight seal with the sidewall of the housing 1401.

[0171] An internal filter media package 1412b is positioned within a first channel 1419a defined by an external filter media package 1412a, for example, within a first central tube 1418a. The internal filter media package 1412b may also include folded filter media, similar to the external filter media package 1412a. Furthermore, the internal filter media package 1412b may include a rolled-up filter media. In various embodiments, the external filter media package 1412a and / or the internal filter media package 1412b may include tetrahedral filter media, origami-style filter media, straw-style filter media, grooved filter media, corrugated filter media, or any other filter media. In some embodiments, the internal filter media package 1412b may define a second channel 1419b, which may have a second central tube (not shown) disposed therein. In a specific embodiment, for example, a first end of the second channel 1419b near the flow reversal chamber 1409 is fluidly sealed to the flow reversal chamber 1409 via a sealant. The second support structure 1416b is disposed at the end of the internal filter media package 1412b near the flow reversal chamber 1409, and may include a grid or mesh. The second radial seal 1430b is disposed around the second support structure 1416b and forms a fluid-tight seal between the second support structure 1416b and the inner surface of the first central tube 1418a.

[0172] In operation, unfiltered fluid enters the first end of the outer filter media package 1412a and flows out from the second end into the flow reversal chamber 1409. The fluid reverses its flow direction in the flow reversal chamber 1409 and enters the inner filter media package 1412b. The fluid flows through the inner filter media package 1412b, from the first end near the flow reversal chamber 1409 to the second end opposite to the first end. The pore size of the inner filter media package 1412b can be smaller than that of the outer filter media package 1412a, allowing the filter element assembly 1410 to provide efficient staged filtration, wherein the outer filter media package 1412a provides a first filtration stage and the inner filter media package 1412b provides a second filtration stage.

[0173] In some embodiments, any of the filter assemblies described herein can be used as a highly efficient bypass filter element in a lubrication system. The flow rate through such a system can be reduced by some type of flow restrictor (e.g., orifice) to decrease the flow rate and thus reduce the pressure drop across the filter element. Furthermore, any wound filter element described herein can be used in place of a centrifugal cartridge filter element. For example, Figure 40This is a schematic diagram of a rotary filter element 1510 including an axial flow filter media package 1512. The axial flow filter media 1512 may include a wound filter media, such as any wound filter media previously described in detail herein. A channel 1519 is defined through the filter media package 1512 along its longitudinal axis. A central tube 1518 is disposed in the channel 1519.

[0174] A support structure 1516 is disposed at the outlet end of the filter media package 1512, through which filtered fluid (e.g., oil or fuel) exits the filter media package 1512. The support structure 1516 may include a mesh or grid. A radial seal 1532 (e.g., an O-ring) is positioned around the second support structure 1516 and configured to form a fluid-tight seal with the sidewall of a housing within which the filter media package 1512 is disposed. In some embodiments, the filter element 1510 may further include an inlet seal 1530 positioned around an inlet end of the filter media package 1512 opposite to the outlet end. The inlet seal 1530 may be configured to form a radial and / or axial seal with the sidewall of the housing and / or the filter head within which the filter element 1510 is disposed.

[0175] Shaft 1572 is positioned in channel 1519. Shaft 1572 is positioned through rotor bushing 1570, which is coupled to the inner surface of center tube 1518 at its end near the outlet end of filter media package 1512. Rotor bushing 1570 can fluidly seal to the inner surface of the housing and prevent fluid leakage between rotor bushing 1570 and center tube 1518. Shaft 1572 can define an axial flow path therethrough. A plurality of openings 1574 are defined in shaft 1572 near the inlet end of filter media package 1512 and are configured to communicate unfiltered fluid from the axial flow path into channel 1519. Rotation of shaft 1572 causes fluid (e.g., oil or fuel) to flow upward to the inlet end of filter media package 1512. The fluid then flows through filter media package 1512 and is filtered.

[0176] In some embodiments, axial flow filter media may also be included in the coalescing filter assembly, such as a static or rotating coalescing filter assembly. For example, Figure 41This is a schematic diagram of a coalescer filter assembly 1600 including an axial flow filter media package 1612 according to an embodiment. The filter assembly 1600 includes a filter housing 1601 defining an internal volume within which filter elements 1610 are disposed. Filter elements 1610 include an axial flow filter media package 1612 defining a channel 1619 therethrough. A radial seal 1630 is positioned around the outlet end of the filter media package 1612 to form a radial seal with the sidewall 1602 of the housing 1601. A cap 1604 is coupled to an end of the housing 1601 opposite to a base 1603 of the housing 1601 and defines an outlet 1606 therein. In some embodiments, the cap 1604 includes a nut plate. In some embodiments, the outer cross-sectional distance of the filter media package 1612 may be substantially equal to the inner cross-sectional distance of the housing 1601, as previously described herein.

[0177] A central tube 1618 is disposed in a channel 1619 and extends to a base 1603 of a housing 1601, such that a first end of the central tube 1618 is coupled to the base 1603, and defines a flow reversal chamber 1609 in the housing 1601 between the end of the filter media package 1612 near the base 1603 and the base 1603, as previously described herein. A plurality of orifices 1623 may be defined in the portion of the central tube 1618 disposed in the flow reversal chamber 1609, allowing fluid (e.g., fuel or oil) to enter the channel 1619 through the orifices 1623 after passing through the filter media package 1612. A second end of the central tube 1618 is coupled to an outlet 1606 via a gasket 1608. The filter media package 1612 is configured to coalesce water droplets contained in the fluid. The coalesced water droplets accumulate in the flow reversal chamber 1609 and can be discharged therefrom.

[0178] refer to Figures 42-44The filter media package 1612 includes a pleated media layer 1613 disposed between layers of a flat media layer 1634. In other embodiments, the filter media package 1612 may include non-pleated, origami-like, straw-like, grooved, corrugated, or any other filter media. A plurality of inlet channels 1615 are formed between a plurality of pleats in the pleated media layer 1613 and a flat media layer 1634, and a plurality of outlet channels 1617 are defined between a plurality of pleats in the pleated media layer 1613 and another flat media layer 1634. The plurality of inlet channels 1615 open at an inlet end of the filter media package 1612 and are fluidly sealed at their outlet ends via a first sealing member 1630. Conversely, the plurality of outlet channels 1617 are sealed at their inlet ends via a second sealing member 1621 and open at their outlet ends of the filter media package 1612. Because the outlet of inlet channel 1615 is sealed, dirty fluid enters inlet channel 1615 and flows through pleated media layer 1613 and flat media layer 1634. Any water present in the fluid coalesces in exit channel 1617 and drips into flow-to-reverse chamber 1609, from which the water can be removed.

[0179] Therefore, by using two to three media layers in an axial flow configuration, the total thickness of the filter media used to form the filter media package 1612 is reduced, and the separator stage of the coalescer can be eliminated. Furthermore, more media layers can be packed into the same volume, thus increasing the visible contaminant capacity and service life while reducing the surface velocity through the filter media 1612. The separator stage is eliminated by using downward-flowing filtered fluid (e.g., gas or aerosol) and gravity to remove coalesced droplets by gravity settling. The coalesced droplets are collected at the bottom of the coalescer, while the clean fluid exits the filter via a hollow central tube. The filter media used to form the filter media package 1612 may also include a capture layer and a discharge layer, and may have an optional pre-filtration layer to remove semi-solid and solid contaminants. Therefore, the filter media can be a composite media.

[0180] Key features of the filter assembly 1600 include: (1) axial flow filtration; (2) design limitations on the pleat height of the pleated media layer 1613; and (3) flow design in the bottom droplet collection and clean fuel return sections of the filter assembly 1600.

[0181] Further extending to item (2) above, when the pleated medium layer 1613 and the flat medium layer 1634 are identical, the released coalesced droplets will be released and migrate toward the center of channel 1619. Here, they will be carried downward by flow and gravity and settle to the bottom of the shell 1601 flowing into the reversal chamber. However, if two different media are used, making the opening of the pleated medium layer 1613 larger (larger aperture, less confinement), they will move closer to the wall of channel 1619 associated with the flat sheet. Depending on the relative differences between the two layers 1613 and 1634, the coalesced droplets may actually contact / impact the flat layer wall. In this case, they can accumulate, further coalesce, and be discharged downward along the wall of the central tube 1618 for separation. In effect, in this case, the flat layer wall becomes the separator stage.

[0182] Regarding item (3), the fold height can limit the size of coalesced droplets and affect the pressure drop across the filter medium 1612. If the height is too small, the coalesced droplets will bridge the channel and restrict flow. Therefore, it is desirable for the fold height to be greater than 1.75 times the diameter of the coalesced droplets. The diameter of the coalesced droplets is rarely known or measurable, but can be estimated using the droplet weight method, which measures surface (or interfacial) tension. Under stagnant conditions, the relationship between the pore size of the discharge layer and the size of the coalesced droplets is approximately:

[0183]

[0184] in:

[0185] γ = interfacial tension between the continuous phase and the dispersed phase.

[0186] D s =Aperture (diameter) of the emission layer,

[0187] ρ = density difference between the dispersed phase and the continuous phase.

[0188] d = diameter of the released droplet

[0189] g = acceleration due to gravity.

[0190] Equation 1 allows the size of the coalesced droplets (and therefore the fold height) to be related to the pore size of the discharge layer, interfacial tension, and fluid density. It should be noted that Equation 1 is only an approximation for droplets formed under static conditions from a capillary (orifice). In the case of a coalescer, the conditions are not static (the continuous phase is flowing), and the droplets are oriented at approximately 90° to the vertical. This means that the calculated droplet size will be overestimated. Orientation affects the droplet shape and the angle at which the droplets form at the moment of separation. These two factors cancel each other out to some extent.

[0191] In some embodiments, the filter assembly may be oriented such that its longitudinal axis is oriented substantially perpendicular to the direction of gravity (e.g., at an angle in the range of 80 to 100 degrees), and may further include a coalescing media layer disposed near the outflow or flow-away end of the filter assembly. For example, Figure 45 This is a side cross-sectional view of a filter assembly 1700 according to an embodiment. The filter assembly 1700 includes a filter housing 1701 (e.g., a shell) defining an internal volume within which a filter element 1710 is disposed. The filter housing 1701 includes a sidewall 1702, a cap 1704 coupled to a first longitudinal end of the filter element 1710, and a base 1703 coupled to a second longitudinal end of the filter element 1710 opposite to the first longitudinal end. A space 1709 is defined between the base 1703 and the filter element 1710 and can serve as a redirection zone to allow filtered fluid (e.g., a fuel or air-fuel mixture) to undergo a change of direction after flowing through the filter element 1710.

[0192] Longitudinal axis A of filter assembly 1710 L The orientation is substantially perpendicular to the gravity vector, for example, at an angle between 80 and 100 degrees. In other embodiments, the filter assembly 1700 may be substantially parallel to the gravity vector (e.g., at an angle in the range of -10 to 10 degrees). The filter element 1710 includes a filter media package 1712, which may include a wound or rolled-up layer of filter media, or may include a generally cylindrical filter media package configured for axial flow. An end cap (not shown) may be coupled to a longitudinal end of the filter media package 1712. The filter media package 1712 defines a central channel in which a central tube 1718 or an outflow tube is disposed.

[0193] A sealing member 1730 is disposed between the radially outer surface of the filter media package 1712 and the radially inner surface of the sidewall 1702 at a first end of the filter media package 1712 near the cap 1704. The sealing member 1730 forms a radial seal between the filter media package 1712 and the sidewall 1702 to prevent unfiltered fluid from flowing around the filter media package 1712.

[0194] In operation, unfiltered fluid flows axially from the first longitudinal end through the filter media package 1712 to the second longitudinal end and is filtered. The filtered fluid is redirected in the redirection zone 1709 to the central tube 1718. The filter assembly 1700 is configured to coalesce water droplets that may be entrained or emulsified by the fuel. For example, as... Figure 45As shown, the coalescing media layer 1717 is disposed near the second longitudinal end such that the coalescing media layer 1717 contacts the second longitudinal end of the filter element 1710. Furthermore, the radially outer edge of the coalescing media layer 1717 is spaced apart from the inner surface of the sidewall 1702 (e.g., having a diameter smaller than the diameter of the sidewall 1702), thereby allowing a portion of the filtered fluid to flow around the coalescing media layer 1711.

[0195] In some embodiments, the coalescing medium layer 1717 includes a first mesh having a first opening of 20 to 30 micrometers (inclusive), the first mesh being supported by a second mesh formed of a more rigid material and having openings in the range of 400 to 600 micrometers (inclusive). In some embodiments, the first and / or second mesh may be formed of a rigid material (e.g., plastic or metal) and may have pores in the range of 500 to 1500 micrometers (inclusive). In other embodiments, the coalescing medium layer 1717 may comprise a monolithic, thicker medium, such as a spun-bound media layer. The coalescing medium layer 1717 is configured to allow fluid (e.g., fuel) to pass freely through it, but impedes the flow of water droplets, causing water droplets to coalesce on the coalescing medium layer 1717. The second mesh with greater rigidity ensures that the coalescing medium layer 1717 remains in contact with the second longitudinal end (i.e., the outflow end) of the filter element 1710 during operation.

[0196] A coalescing medium layer is used to coalesce water droplets into larger droplets that are less likely to flow back through the central tube 1718. Having multiple coalescing medium layers 1717 can further promote coalescence. The coalesced droplets then drip along the gravity vector and can be collected in the housing (e.g., in the redirection zone 1709 or on portions of the sidewalls at a lower height relative to gravity) and can be removed later. In some embodiments, the central tube 1718 extends a short distance (e.g., in the range of 2 mm to 15 mm) including through the surface of the coalescing medium layer 1717, such that the higher velocity region near the inlet of the central tube 1718 is spaced apart from the coalesced droplets, thereby further reducing entrainment. In some embodiments, a first end of the central tube 1718 near the base 1703 can be flared outward (e.g., shaped like a horn or trumpet) to prevent water droplets from entering the central tube 1718 and to promote drainage perpendicular to the fluid flow.

[0197] A central tube 1718 extends through the coalescing medium layer 1717 and may be interference-fitted with a corresponding opening defined in the coalescing medium layer 1717. This allows water droplets to preferably flow through or around the coalescing medium layer 1717. However, water droplets do not cross the interface between the central tube 1718 and the coalescing medium layer 1717, through which the central tube 1718 passes. For example, the inner diameter of the hole in the coalescing medium layer 1717 through which the central tube 1718 passes corresponds to the outer diameter of the central tube 1718, such that the central tube 1718 forms a radial seal with the hole. In some embodiments, a circumferential retaining flange 1716 may be disposed around the central tube 1718 near a second longitudinal end of the filter element 1710 and configured to hold the coalescing medium layer 1717 in place and improve its axial seal.

[0198] Figure 46 This is a side cross-sectional view of a filter assembly 1800 according to another embodiment. The filter assembly 1800 is similar to the filter assembly 1700 and includes similar components, except for the following differences. A coalescing media layer 1817 is spaced apart from a second longitudinal end of the filter element 1710, such that a gap G exists between the coalescing media layer 1817 and the second longitudinal end of the filter element 1710. Furthermore, the coalescing media layer 1817 has a radial cross-section (e.g., outer diameter) corresponding to the inner radial cross-section (e.g., diameter) of the sidewall 1702, such that the radially outer edge of the coalescing media layer 1817 contacts the inner surface of the sidewall 1702. In some embodiments, the radially outer edge of the coalescing media layer 1817 may be coupled (e.g., via an adhesive) to the inner surface of the sidewall 1702. This ensures that all fluid flow passes through the coalescing media layer 1817.

[0199] Figure 47 This is a side cross-sectional view of a filter assembly 1900 according to another embodiment. The filter assembly 1900 is substantially similar to the filter assembly 1700, except for the following differences. A coalescing media layer 1917 is used, which has a substantially larger radial cross-section (e.g., diameter) relative to the radially inner cross-section (e.g., diameter) of the sidewall 1702. This results in a portion of the coalescing media layer 1917 being sandwiched between the outer surface of the filter element 1710 and the inner surface of the sidewall 1702, thereby providing a tight fit with the filter housing 1701.

[0200] In some embodiments, the filter media package includes a plurality of filter media layers, with a substrate interposed between these filter media layers. For example, Figure 48A front perspective view of a filter media package or block 2012 according to an embodiment is shown. The filter media package 2012 includes a first filter media layer 2014a and a second filter media layer 2014b, with a substrate 2030 interposed therebetween. Each of the first filter media layer 2014a and the second filter media layer 2014b may include a non-wrinkled filter media, which may be laminated to the substrate or frame 2030, for example, via adhesive, thermal bonding, acoustic welding, or any other suitable bonding method. Although only the first filter media layer 2014a and the second filter media layer 2014b are shown, any number of filter media layers may be stacked until a filter media package flow area of ​​desired thickness is obtained. In some embodiments, each filter media layer 2014a, 2014b may have a thickness ranging from 1 micrometer to 3 micrometers (inclusive).

[0201] The substrate 2030 is configured to provide a plurality of spaced-apart flow channels between the first filter media layer 2014a and the second filter media layer 2014b, with one end of each flow channel open and the other end closed. For example, the substrate 2030 may have, for example, Figure 48 The fluid flows between filter media layers 2014a and 2014b into filter media package 2012, entering the... Figure 54 The flow channels are shown in the open end. Because the opposite ends of the flow channels are closed, fluid is forced to flow through the filter media layers 2014a, 2014b into adjacent flow channels that define the outlet of the fluid out of the filter media package 2012.

[0202] Figure 49 Another embodiment of filter media package 2012a is shown. The filter media comprises multiple groups 2013 of filter media layers 2014, each including a substrate 2030 disposed therebetween. The substrate 2030 may also be disposed on the outermost filter media layer 2014. A discharge layer 2050 is disposed between each group of filter media layers 2014 and can be configured to separate water droplets from fluid flowing through the filter media layers 2014. Furthermore, when fluid flows from the inlet channel to the outlet channel defined by the substrate 2030, the fluid must flow through the discharge port and both filter media layers 2014.

[0203] Filter media packages 2012 and 2012a allow the use of relatively thin or less rigid filter media that may be sensitive to pleating, such as filter media comprising nanoscale fibers. In some embodiments, filter media packages 2012 and 2012a can be placed or clamped within a rigid external frame. For example, Figure 50A filter media package 2012 encapsulated in a rigid frame 2006 (e.g., a plastic or metal frame) is shown to form a filter element 2010, which can be inserted into the internal volume 2004 of a filter housing 2002 configured to receive the filter element 2010. The filter element 2010 and the filter housing 2002 form a filter cartridge that can be mounted in a corresponding mounting structure. Filter media packages 2012, 2012a can be arranged in series to achieve "filter-in-filter" filtration. Furthermore, the compact shape of the filter element 2010 allows for more efficient use of installation space (e.g., on an engine) than conventional cylindrical filter packages.

[0204] Furthermore, the rigid frame 2006 can also form a cover 2014 for the filter housing 2002, which seals the insertion end of the internal volume 2004 when the filter element 2010 is inserted into the internal volume 2004. In this way, the frame 2006 forms part of the filter housing 2002. Additionally, a "no-filter, no-operation" state can be provided, meaning the filter cartridge does not operate until the filter element 2010 is securely inserted into the internal volume 2004 and the internal volume 2004 is sealed by the cover 2014.

[0205] In some embodiments, the filter media may comprise a flat sheet media. Pleating and / or embedding can generate external noise, which can degrade the performance of filter assemblies comprising such filter media. For example, when the filter media layer is pleated, the fibers of the filter media may stretch, causing at least some fibers to break, making the pleated portions of the filter media its weakest points. Furthermore, embedding may expose the fibers to some heat exchange and degrade fiber performance.

[0206] on the contrary, Figure 51 This is a perspective view of a rolled-up filter media package 2112, including a backing sheet 2116 and a filter media layer 2114, according to an embodiment. The filter media package 2112 may be vertically oriented and configured for axial flow. The filter media layer 2114 is flat and is rolled up together with the backing sheet 2116. The backing sheet 2116 is formed of a robust and impermeable material, such as Kolon, corrugated aluminum, rubber with molded channels, or any other suitable material. The backing sheet 2116 may have a plurality of grooves 2117 defined thereon (e.g., grooved). The backing sheet 2116 is made of a more robust material than the filter media layer 2114 and provides support for the filter media layer 2114 in high-pressure applications (e.g., liquid filtration applications where the pressure differential may be up to 4 bar). Because the filter media layer 2114 is flat, the plurality of grooves 2117 form flow channels on either side of the filter media layer 2114.

[0207] To elaborate further, Figure 52 This is a perspective view of a flat backing sheet 2116, showing a plurality of grooves 2117 defined therein. For example, the backing sheet 2116 may include a corrugated sheet having corrugations that provide the plurality of grooves 2117. Figure 53 This is a side perspective view of the filter media package 2112, in which the backing sheet 2116 and the filter media layer 2114 are partially unfolded, and Figure 54 yes Figure 53 The filter media package along Figure 53 The side cross-section diagram taken from line AA in the figure.

[0208] A first adhesive layer 2115 is disposed on the backing sheet 2116, near the first axial edge 2111 of the backing sheet 2116, and bonded to the corresponding first axial edge of the filter media layer 2114, such that a first flow channel 2121a (e.g., an inlet channel) is formed between the backing sheet 2116 and the first side of the filter media layer 2114. Furthermore, a second adhesive layer 2119 is disposed on the second axial edge of the filter media layer 2114, near the second axial edge 2113 of the backing sheet 2116, and is bonded to the backing sheet 2116 at this location when the filter media layer 2114 and the backing sheet 2116 are rolled up. In this way, a second flow channel 2121b (e.g., an outlet channel) is formed between the backing sheet 2116 and the second side of the filter media layer 2114 opposite to the first side. The first adhesive layer 2115 blocks the end of the first flow channel 2121a opposite to its inlet, thereby allowing fluid (e.g., fuel, lubricant, air, etc.) to flow through the filter media layer 2114 into the second flow channel 2121b and subsequently out of the filter media package 2112.

[0209] As used herein, the terms “about” and “approximately” generally refer to plus or minus 10% of the stated value. For example, about 0.5 includes 0.45 and 0.55, about 10 includes 9 to 11, and about 1000 includes 900 to 1100.

[0210] It should be noted that the term "example" used herein to describe the various embodiments is intended to mean that these embodiments are possible examples, representations and / or illustrations of possible embodiments (and this term is not intended to mean that these embodiments must be particular or excellent examples).

[0211] As used herein, the term "substantially" and similar terms are intended to have a broad meaning consistent with usage commonly accepted by one of ordinary skill in the art to which this disclosure pertains. Those skilled in the art who read this disclosure will understand that these terms are intended to allow for the description of certain features described and claimed, without limiting the scope of these features to the precise numerical ranges provided. Therefore, these terms should be interpreted as indicating that non-substantial or insignificant modifications or alterations to the described and claimed subject matter (e.g., within ±5 percent of a given angle or other value) are considered to be within the scope of the invention set forth in the appended claims. The term "approximately," when used with numerical values, refers to ±5 percent of the relevant numerical value.

[0212] As used herein, the terms “link,” “connection,” and similar terms refer to the direct or indirect linking of two components to each other. Such a link can be fixed (e.g., permanent) or movable (e.g., removable or releasable). Such a link can be achieved by the two components, or two components and any additional intermediate components, being integrally formed into a single unit, or by the two components, or two components and any additional intermediate components, being attached to each other.

[0213] It is important to note that the structures and arrangements of the various exemplary embodiments are merely illustrative. Although only a few embodiments are described in detail in this disclosure, those skilled in the art will readily recognize that many modifications (e.g., variations in the size, dimensions, structure, shape and proportion of various elements, values ​​of parameters, mounting arrangements, use of materials, color, orientation, etc.) are possible without substantially departing from the novel teachings and advantages of the subject matter described herein. Other substitutions, modifications, changes, and omissions may also be made in the design, operating conditions, and arrangements of the various exemplary embodiments without departing from the scope of the embodiments described herein.

[0214] While this specification contains numerous specific implementation details, these should not be construed as limiting any embodiment or the scope of the claims, but rather as descriptions of features specific to particular implementations of particular embodiments. Certain features described in the context of individual embodiments may also be implemented in combinations of individual embodiments. Conversely, various features described in the context of individual embodiments may also be implemented individually in multiple embodiments or in any suitable sub-combination. Furthermore, although features may be described above as functioning in certain combinations, and even initially claimed in this way, in some cases, one or more features from a claimed combination may be removed from that combination, and the claimed combination may refer to a sub-combination or a variation of a sub-combination.

Claims

1. A filter assembly, comprising: Filter housing, which defines the internal volume, and A filter element disposed within the internal volume, the filter element comprising an axial flow filter media package configured to allow fluid to flow therethrough in a first direction along a longitudinal axis between a first longitudinal end and a second longitudinal end of the axial flow filter media package, the axial flow filter media package comprising a backing sheet and a filter media layer wound with the backing sheet to form a wound filter media package, the backing sheet having a plurality of grooves defined thereon, the backing sheet and the filter media layer together defining: --A plurality of first flow channels, the plurality of first flow channels being open at the first longitudinal end and sealed at the second longitudinal end; and --A plurality of second flow channels, the plurality of second flow channels being open at a second longitudinal end and sealed at a first longitudinal end, a filter media layer disposed between the plurality of first flow channels and the plurality of second flow channels, such that fluid axially entering the plurality of first flow channels is filtered through the filter media layer and axially exits from the plurality of second flow channels through the second longitudinal end; the filter housing and the axial flow filter media package are arranged such that, during operation, fluid flows around the axial flow filter media package in a first direction and flows through the axial flow filter media package in a second direction opposite to the first direction; the filter element and the filter housing together define a flow reversal chamber, the flow reversal chamber being configured to change the flow direction of the fluid from the first direction to the second direction opposite to the first direction when the fluid flows through the filter assembly.

2. The filter assembly of claim 1, wherein the axial flow filter media package defines a central channel extending along the longitudinal axis of the filter element, and wherein the axial flow filter media package is further configured to allow the fluid to flow through the central channel in the second direction.

3. The filter assembly of claim 2, wherein the filter element further comprises a central tube positioned within the central channel, the central tube being connected to one of (i) the flow reversal chamber and (ii) the inlet and outlet of the filter assembly.

4. The filter assembly according to any one of claims 1-3, wherein the wound filter media package comprises a cylindrical roll of the filter media layer and the backing sheet rolled together.

5. The filter assembly of claim 4, wherein the backing sheet is made of a material that is more robust than the filter media layer.

6. The filter assembly according to any one of claims 1-3, wherein the filter housing includes a base and a sidewall extending perpendicularly from an outer edge of the base, and the filter assembly further includes a cover coupled to an end of the filter housing remote from the base, the cover defining both an inlet and an outlet of the filter assembly.

7. The filter assembly according to any one of claims 1-3, wherein the filter housing includes a base and a sidewall extending perpendicularly to the base from an outer edge of the base, wherein the flow reversal chamber is defined at least partially by the base.

8. The filter assembly according to any one of claims 1-3, wherein the internal volume of the filter housing has an inner cross-section defining an inner cross-sectional distance, and at least a portion of the axial flow filter media package has an outer cross-section defining an outer cross-sectional distance, the outer cross-sectional distance being substantially equal to the inner cross-sectional distance.

9. The filter assembly according to any one of claims 1-3, further comprising a sealing member disposed between the axial flow filter media package and the sidewall of the filter housing, such that the fluid is prevented from flowing around the outer diameter of the axial flow filter media package.

10. A filter element configured to be disposed within a filter housing, the filter element comprising an axial flow filter media package configured to allow fluid to flow therethrough along a longitudinal axis in a first direction between a first longitudinal end and a second longitudinal end of the axial flow filter media package. The axial flow filter media package includes a backing sheet and a filter media layer, the filter media layer being wound with the backing sheet to form a wound filter media package, the backing sheet having a plurality of grooves defined thereon, the backing sheet and the filter media layer together defining: --A plurality of first flow channels, the plurality of first flow channels being open at the first longitudinal end and sealed at the second longitudinal end; and --A plurality of second flow channels, the plurality of second flow channels being open at the second longitudinal end and sealed at the first longitudinal end, the filter media layer being disposed between the plurality of first flow channels and the plurality of second flow channels, such that fluid axially entering the plurality of first flow channels is filtered through the filter media layer and axially exits from the plurality of second flow channels through the second longitudinal end; The axial flow filter media package is configured to be disposed within the filter housing such that, during operation, the fluid flows around the axial flow filter media package in a first direction and flows through the axial flow filter media package in a second direction opposite to the first direction, the axial flow filter media package defining a central channel extending along the longitudinal axis of the filter element.

11. The filter element of claim 10, wherein the filter media layer comprises a fully synthetic nanofiber media paired with the inflow mesh layer and the outflow mesh layer.

12. The filter element of claim 10, wherein the filter element further comprises a central tube positioned within the central channel.

13. The filter element according to any one of claims 10-12, wherein the wound filter media package comprises a cylindrical roll of the filter media layer and the backing sheet wound together.

14. The filter element according to any one of claims 10-12, further comprising a support structure connected to a longitudinal end of the axial flow filter media package, the support structure being configured to form a fluid-tight seal against the housing.

15. A filter element configured to be disposed within a filter housing having an inner cross-section defining a maximum inner cross-sectional distance, the filter element comprising: An axial flow filter media package includes a backing sheet and a filter media layer wound with the backing sheet to form a wound filter media package. The backing sheet has a plurality of grooves defined thereon, and the backing sheet and the filter media layer together define: --A plurality of first flow channels, said plurality of first flow channels being open at a first longitudinal end and sealed at a second longitudinal end; and --A plurality of second flow channels, the plurality of second flow channels being open at the second longitudinal end and sealed at the first longitudinal end, the filter media layer being disposed between the plurality of first flow channels and the plurality of second flow channels, such that fluid axially entering the plurality of first flow channels is filtered through the filter media layer and axially exits from the plurality of second flow channels through the second longitudinal end; The axial flow filter media pack is configured to be arranged within the filter housing such that, during operation, fluid flows around the axial flow filter media pack in a first direction and flows through the axial flow filter media pack in a second direction opposite to the first direction. At least a portion of the axial flow filter media pack has an outer cross-section defining a maximum outer cross-sectional distance, the maximum outer cross-sectional distance being substantially equal to the maximum inner cross-sectional distance of the filter housing. and A support structure is attached to at least one longitudinal end of the axial flow filter media package and configured to contact the surface of the filter housing to form a fluid-tight seal with the filter housing.

16. The filter element of claim 15, wherein the axial flow filter media package is configured to allow fluid to flow through an axial end of the axial flow filter media package, the axial flow filter media package defining a central channel extending along the longitudinal axis of the filter element.

17. A filter element configured to be disposed within a filter housing having an inner cross-section defining an inner cross-sectional distance, the filter element comprising: An axial flow filter media package has a channel defined through it along the longitudinal axis of the filter element. The axial flow filter media package is configured to allow fluid to flow through it in a first direction along the longitudinal axis and be filtered to produce filtered fluid. The filtered fluid flows through the channel toward an outlet in a second direction opposite to the first direction. The axial flow filter media package includes a backing sheet and a filter media layer wound around the backing sheet to form a wound filter media package. The backing sheet has a plurality of grooves defined thereon. The backing sheet and the filter media layer together define: --A plurality of first flow channels, said plurality of first flow channels being open at a first longitudinal end and sealed at a second longitudinal end; and --A plurality of second flow channels, the plurality of second flow channels being open at the second longitudinal end and sealed at the first longitudinal end, the filter media layer being disposed between the plurality of first flow channels and the plurality of second flow channels, such that fluid axially entering the plurality of first flow channels is filtered through the filter media layer and axially exits from the plurality of second flow channels through the second longitudinal end; The axial flow filter media package is configured to be arranged within the filter housing such that, during operation, fluid flows around the axial flow filter media package in a first direction and flows through the axial flow filter media package in a second direction opposite to the first direction. At least a portion of the axial flow filter media package has an outer cross-section defining an outer cross-sectional distance that is substantially equal to the inner cross-sectional distance of the filter housing. and A support structure is attached to at least one end of the axial flow filter media package.

18. The filter element of claim 17, wherein the filter element further comprises a central tube positioned within the channel.

Images