Filter medium, filter medium package, and filter element

Abstract

An embodiment includes an air filtration media element (10) that includes multiple layers of fluted media, each layer including a facing sheet and a fluted sheet, the fluted sheet including a first plurality of flutes and a second plurality of flutes, the first plurality of flutes and the second plurality of flutes arranged in a parallel flow configuration; wherein the first plurality of flutes and the second plurality of flutes exhibit regularly repeating differences in flute shape, flute size, flute height, flute width, flute cross-sectional area, or filtration media.

Description

[0001] This application is a PCT international patent application filed on June 11, 2019 in the name of the applicant designated in all countries, Donaldson Company, Inc., a national company of the United States, and the inventors designated in all countries, Daniel E. Adamek, a citizen of the United States; Scott M. Brown, a citizen of the United States; and Mark A. Sala, a citizen of the United States, and claims the priority of U.S. Provisional Patent Application No. 62 / 683,542 filed on June 11, 2018, the content of which is incorporated herein by reference in its entirety. Technical Field

[0002] Embodiments herein relate to filter media, filter media packs, filter elements, air cleaners, and methods of making and using filter media, media packs, elements, and air cleaners. More specifically, embodiments herein relate to z-flow filter media, media packs, and filter elements. Background Art

[0003] The z-flow filter media, such as described in U.S. Patent No. 7,959,702 to inventor Rocklitz, has multiple layers of media. Each layer has a slotted sheet, a facing sheet, and a plurality of slots extending from a first face of the filter media element to a second face. A first portion of the plurality of slots is closed to unfiltered air flowing into the first portion of the plurality of slots, and a second portion of the plurality of slots is closed to unfiltered air flowing out of the second portion of the plurality of slots. Air entering the slots on one face of the media element is filtered by the filter media before flowing out of the slots on the other face of the media element.

[0004] Although z-flow media has many benefits, there is still a need for improved filtration performance, including filter media, media packs, and elements having a reduced pressure drop across the element and / or an improved particle loading capacity. Summary of the Invention

[0005] This application relates to filter media, filter media packs, filter elements, and air cleaners having two or more different media configurations, and methods of making and using the media, media packs, filter elements, and air cleaners. The different media configurations can be, for example, different slot geometries in z-flow filter media. Using two or more different media configurations allows for improved performance, such as a reduced pressure drop and / or an increased loading capacity, as compared to using a single media configuration.

[0006] In an exemplary implementation, two different media portions are combined into a single filter element, and these two media portions have different pressure drop and loading characteristics. The difference in pressure drop and loading characteristics between the media portions is typically less than the normal variation observed from manufacturing variations in the filter element. Thus, for a particular measurement and varying parameter, the difference will typically be at least 5%, and more typically at least 10% for a particular measurement and varying parameter.

[0007] In an exemplary configuration, the first media portion has a lower initial pressure drop than the second media portion, while the second media portion has a greater dust holding capacity than the first media portion. In some configurations, the combination of these two media portions results in an element that has a better performance than a media element made from only one of these media and better than the performance achieved by simply averaging the performance of each media portion. Thus, relative to a media element made from only one media or the other, a hybrid filter element can (for example) exhibit a reduced initial pressure drop but also an increased loading.

[0008] An exemplary embodiment is an air filter element for removing particulate matter from an air stream, the air filter element comprising:

[0009] a) a first plurality of slots; and

[0010] b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of slots exhibit a difference from the first plurality of slots in slot shape, slot size, slot height, slot width, slot length, slot cross-sectional area, or filter medium;

[0011] wherein the first plurality of slots and the second plurality of slots have a common upstream face and a common downstream face; and

[0012] wherein, when the filter element is loaded with dust at a substantially constant velocity:

[0013] a) the first plurality of slots and the second plurality of slots have substantially equal initial pressure drops from the upstream face to the downstream face;

[0014] b) the initial velocity of the first plurality of slots is greater than the initial velocity of the second plurality of slots;

[0015] c) during dust loading:

[0016] i) when the velocities of the first plurality of slots and the second plurality of slots vary relative to each other, the pressure drops across the first plurality of slots and the second plurality of slots remain substantially equal relative to each other; and

[0017] ii) The speed across the first plurality of slots decreases, and the speed across the second plurality of slots increases, at least until the speed across the second plurality of slots is greater than the speed across the first plurality of slots.

[0018] In an embodiment, the transition from the speed across the first plurality of slots being greater than the speed across the second plurality of slots to the speed across the second plurality of slots being greater than the speed across the first plurality of slots occurs before the media element is loaded to 10% of its dust loading capacity.

[0019] In an embodiment, the transition from the speed across the first plurality of slots being greater than the speed across the second plurality of slots to the speed across the second plurality of slots being greater than the speed across the first plurality of slots occurs before the media element is loaded to 15% of its dust loading capacity.

[0020] In an embodiment, the transition from the speed across the first plurality of slots being greater than the speed across the second plurality of slots to the speed across the second plurality of slots being greater than the speed across the first plurality of slots occurs before the media element is loaded to 20% of its dust loading capacity.

[0021] The initial pressure drop refers to the first part of the media loading, such as less than 1 inch of water, less than 2 inches of water, or less than 3, 4, or 5 inches of water. The initial pressure drop can also be measured (for example) at the point where the element reaches 1%, 2%, 5% of the maximum pressure drop, or 10% of the pressure drop.

[0022] For example, the slot height can vary such that the individual layers of media have varying heights, multiple layers of media have different heights, or larger portions of the media have different heights.

[0023] The flow through these different layers and portions of the media is typically a parallel flow. As used herein, the term "parallel" refers to a configuration in which the fluid flow to be filtered is dispersed into the first plurality of slots and the second plurality of slots and then typically converges again. Thus, "parallel" does not require that the slots themselves be arranged in a geometrically parallel configuration (although they often are), but rather that the plurality of slots present a parallel flow relative to each other. Thus, "parallel" flow is contrasted with "serial" flow (wherein in serial flow, the flow comes from the first plurality of slots and then enters the second plurality of slots).

[0024] Structures made in accordance with the disclosures herein can, for example, permit improved pressure drop and dust loading relative to filter media elements and elements made of a single media type. Additionally, in some implementations, more media can be added to a given volume without significantly increasing the initial pressure drop. In this way, a media structure can be produced that has a relatively low initial pressure drop while still having a relatively high dust loading capacity. Such improvements can be obtained by combining a first media having a low initial pressure drop (but low dust loading capacity) with a second media having a higher initial pressure drop (and higher dust loading capacity). In some embodiments, the resulting combined media exhibits an initial pressure drop similar to the first media but has the dust loading of the second media.

[0025] The benefits of hybrid media structures can also be utilized to obtain more media in a given volume and to load more dust on a given media surface area. Thus, improved media performance can be obtained while having less media.

[0026] In an exemplary embodiment, an air filter element for removing particulates from an air stream includes: a) a first plurality of slots; and b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of slots being different from the first plurality of slots in slot shape, slot size, slot height, slot width, slot length, slot cross-sectional area, or filter media; wherein the first plurality of slots and the second plurality of slots have a common upstream face and a common downstream face; and wherein, when the filter element is loaded with dust at a substantially constant velocity, the first plurality of slots and the second plurality of slots perform as follows:

[0027] a) The first plurality of slots and the second plurality of slots have a substantially equal initial pressure drop from the upstream face to the downstream face;

[0028] b) The initial velocity of the first plurality of slots is greater than the initial velocity of the second plurality of slots;

[0029] c) During dust loading, as Figure 3A shown:

[0030] i) When the velocities of the first plurality of slots and the second plurality of slots change relative to each other, the pressure drops across the first plurality of slots and the second plurality of slots remain substantially equal relative to each other; and

[0031] ii) The velocity across the first plurality of slots decreases and the velocity across the second plurality of slots increases, at least until the velocity across the second plurality of slots is greater than the velocity across the first plurality of slots.

[0032] In an exemplary implementation, an air filtration media element for removing particulates from an air stream includes a) a first plurality of channels; and b) a second plurality of channels arranged in a parallel flow configuration with the first plurality of channels; the second plurality of channels exhibit differences from the first plurality of channels in terms of channel shape, channel size, channel height, channel width, channel cross-sectional area, channel length, or filtration media; wherein the first plurality of channels and the second plurality of channels have a common upstream face and a common downstream face. When the filter element is loaded with dust, the first plurality of channels and the second plurality of channels will perform as follows:

[0033] a) When the first plurality of channels and the second plurality of channels are independently tested at the same media element velocity, the first plurality of channels have an initial pressure drop ΔP 2,i lower than the initial pressure drop ΔP 1,i across the second plurality of channels; and the initial slope Δ(ΔP 1,i / L 1,i ) a of the pressure drop / loading curve of the first plurality of channels at time a is greater than the initial slope Δ(ΔP 2,i / L 2,i ) a of the pressure drop / loading curve of the second plurality of channels:

[0034] Δ(ΔP 1,i / L 1,i ) a >Δ(ΔP 2,i / L 2,i ) a

[0035] b) When the first plurality of channels and the second plurality of channels are combined and tested simultaneously in parallel flow, the initial velocity V 1,a of the first plurality of channels at time a is greater than the initial velocity V 2,a of the second plurality of channels at time a:

[0036] V 1,a >V 2,a

[0037] c) When the first plurality of channels and the second plurality of channels are combined and tested simultaneously in parallel flow, the intermediate second velocity V 1,b of the first plurality of channels at a subsequent time b is equal to the intermediate velocity V 2,b of the second plurality of channels:

[0038] V 1,b =V 2,b

[0039] d) When the first plurality of channels and the second plurality of channels are combined and tested simultaneously in parallel flow, the third velocity V1,c a third velocity V less than the second plurality of slots 2,c :

[0040] V 1,c < V 2,c .

[0041] In an exemplary implementation, an air filtration element for removing particulates from an air stream includes: a) a first plurality of slots; and b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of slots exhibiting a difference from the first plurality of slots in slot shape, slot size, slot height, slot width, slot cross-sectional area, slot length, or filter medium; wherein the first plurality of slots and the second plurality of slots have a common upstream face and a common downstream face. When simultaneously loading dust under parallel flow conditions and when the load reaches the point where the pressure drop across the media element is at least 10 inches of water, the first plurality of slots and the second plurality of slots perform as follows:

[0042] a) The time-averaged velocity of the first plurality of slots is less than the time-averaged velocity of the entire filter element , and the time-averaged velocity of the second plurality of slots is greater than the time-averaged velocity of the filter element

[0043]

[0044]

[0045] b) The load change ΔL1 of the first plurality of slots is equal to the load of the first plurality of slots measured at the time-averaged velocity L of the first plurality of slots 1,(V1 avg) minus the load of the first plurality of slots measured at the time-averaged velocity L of the element 1,(V元件avg) :

[0046] ΔL 1＝ L 1,(V1 avg) -L 1,(V元件avg)

[0047] ΔL1 > 0

[0048] c) The load change ΔL2 of the second plurality of slots is equal to the load of the second plurality of slots measured at the time-averaged velocity L of the second plurality of slots 2,(V2 avg) minus the load of the second plurality of slots measured at the time-averaged velocity L of the element 2,(V元件avg) :

[0049] ΔL 2＝ L 2,(V2avg) -L 2,(V元件avg)

[0050] ΔL2 < 0

[0051] d) The sum of ΔL1 and ΔL2 is greater than 0:

[0052] ΔL1 + ΔL2 > 0.

[0053] In an exemplary implementation, a filter media element for removing particulates from an air stream includes: a) a first plurality of slots; and b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of slots exhibit differences from the first plurality of slots in slot shape, slot size, slot height, slot width, slot length, slot cross-sectional area, or filter media; wherein the first plurality of slots and the second plurality of slots have a common upstream face and a common downstream face; and wherein the first plurality of slots and the second plurality of slots perform as follows:

[0054] i) The pressure drop ΔP increases as the flow rate Q increases;

[0055] ii) Before loading, when the first plurality of slots and the second plurality of slots are tested independently and at the same velocity, the first plurality of slots have an initial pressure drop ΔP 2,0 lower than the initial pressure drop ΔP 1,0 ;

[0056] ΔP 1,0 < ΔP 2,0

[0057] iii) When tested in parallel, the velocity of the first plurality of slots before loading is greater than the average air filter element velocity before loading, and the velocity of the second plurality of slots before loading is less than the average air filter media element velocity before loading;

[0058] V 1,0 > V (元件平均),0

[0059] V 2,0 < V (元件平均),0

[0060] v) When tested in parallel, the pressure drop difference Δ(ΔP1) is equal to the pressure drop of the first plurality of slots before loading tested at the first plurality of slots velocity ΔP 1,0,(V1,0) minus the pressure drop of the first plurality of slots before loading tested at the filter element average velocity ΔP 1,0,(V元件avg,0) :

[0061] Δ(ΔP1) = ΔP 1,0,(V1,0) - ΔP 1,0,(V元件avg,0)

[0062] v) When testing is performed in parallel, the pressure drop difference Δ(ΔP2) of the second plurality of slots is equal to the pressure drop of the second plurality of slots before the load tested at the second plurality of slot velocities ΔP 2,0,(V2,0) minus the pressure drop of the second plurality of slots before the load tested at the filter element average velocity ΔP 2,0,(V元件avg,0) :

[0063] Δ(ΔP2) = ΔP 2,0,(V2,0) -ΔP 2,0,(V元件avg,0)

[0064] d) The sum of Δ(ΔP1) and Δ(ΔP2) is greater than 0:

[0065] Δ(ΔP1) + Δ(ΔP2) < 0.

[0066] In an exemplary configuration, the first media element may comprise, for example, about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of the media element (measured by package volume); and the second media element may comprise, for example, about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of the media element (measured by package volume). As used herein, package volume means the total volume occupied by the media element when measuring the area contained within the perimeter of the package. Thus, the package volume may include the media itself, as well as the open upstream volume into which dust may be loaded and the downstream volume through which filtered air exits the media element. Alternatively, the first plurality of slots constitute 20% to 40% of the package volume, and the second plurality of slots constitute 60% to 80% of the package volume. In other implementations, the first plurality of slots constitute 40% to 60% of the package volume, and the second plurality of slots constitute 60% to 40% of the package volume. In yet another implementation, the first plurality of slots constitute 60% to 90% of the inlet face of the media element, and the second plurality of slots constitute 40% to 10% of the package volume.

[0067] In such an exemplary structure, the first media element can be, for example, about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of the media element (measured by media surface area); and the second media can be, for example, about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of the media element (measured by media surface area). As used herein, the package surface area means the total surface area of the media in each media element in the case where the media element is disassembled and the media is stretched out. Alternatively, the first plurality of slots constitute 20% to 40% of the media surface area, and the second plurality of slots constitute 60% to 80% of the media surface area. In other implementations, the first plurality of slots constitute 40% to 60% of the inlet face of the media surface area, and the second plurality of slots constitute 60% to 40% of the media surface area package. In yet another implementation, the first plurality of slots constitute 60% to 90% of the media surface area, and the second plurality of slots constitute 40% to 10% of the media surface area. The media element can also be characterized by the portion of the inlet face occupied by a particular media type. In some implementations, the first media element (including the first plurality of slots) constitutes 10% to 90% of the inlet face of the media element, such as 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of the inlet face of the media element; and the second media element (including the second plurality of slots) constitutes 90% to 10% of the inlet face of the media element, such as 90%, 80%, 70%, 60%, 50%, 40%, 30%, 20%, or 10% of the inlet face of the media element. Alternatively, the first plurality of slots constitute 20% to 40% of the inlet face of the media element, and the second plurality of slots constitute 60% to 80% of the inlet face of the media element. In other implementations, the first plurality of slots constitute 40% to 60% of the inlet face of the media element, and the second plurality of slots constitute 60% to 40% of the inlet face of the media element. In yet another implementation, the first plurality of slots constitute 60% to 90% of the inlet face of the media element, and the second plurality of slots constitute 40% to 10% of the inlet face of the media element.

[0068] Another embodiment of the filter media element includes a third plurality of slots arranged in a parallel flow arrangement with the first plurality of slots and the second plurality of slots; wherein the first plurality of slots, the second plurality of slots, and the third plurality of slots exhibit regularly repeating differences in slot shape, slot size, slot height, slot width, slot cross-sectional area, taper, or filter media. Optionally, each of the first plurality of slots, the second plurality of slots, and the third plurality of slots is arranged in a separate plurality of layers. It should be understood that in some implementations, more than three pluralities of slots are arranged in a parallel flow arrangement, wherein each of the pluralities of slots exhibits differences in slot shape, slot size, slot height, slot width, slot cross-sectional area, or filter media. Generally, these differences in slot characteristics are repetitive, often regularly repetitive.

[0069] In an exemplary structure having three types of slots, a first slot, a second slot, and a third slot can be selected such that the first plurality of slots constitute 20% to 50% of the volume of the media element, such as 20%, 30%, 40%, or 50% of the volume of the media element; the second plurality of slots constitute 20% to 50% of the volume of the package, such as 20%, 30%, 40%, or 50% of the volume of the media element; and the third plurality of slots constitute 20% to 50% of the volume of the media element, such as 20%, 30%, 40%, or 50% of the volume of the media element.

[0070] In an exemplary structure having three types of slots, a first slot, a second slot, and a third slot can be selected such that the first plurality of slots constitute 20% to 50% of the media surface area of the media element, such as 20%, 30%, 40%, or 50% of the media surface area of the filter media element; the second plurality of slots constitute 20% to 50% of the media surface area of the media element, such as 20%, 30%, 40%, or 50% of the media surface area of the media element; and the third plurality of slots constitute 20% to 50% of the media surface area of the media element, such as 20%, 30%, 40%, or 50% of the surface area of the media element.

[0071] In an exemplary structure having three types of slots, a first slot, a second slot, and a third slot can be selected such that the first plurality of slots constitute 20% to 50% of the inlet face of the media element, such as 20%, 30%, 40%, or 50% of the inlet face of the filter media element; the second plurality of slots constitute 20% to 50% of the inlet face of the media element, such as 20%, 30%, 40%, or 50% of the inlet face of the filter media element; and the third plurality of slots constitute 20% to 50% of the inlet face of the media element, such as 20%, 30%, 40%, or 50% of the inlet face of the media element.

[0072] An exemplary air filter media element has multiple layers of slotted z - flow media. In some structures, each layer of media has a facing sheet and a slotted sheet. Each slotted sheet includes a plurality of slots that exhibit regularly repeating differences in slot shape, slot size, slot height, slot width, slot cross - sectional area, or filter media. These plurality of slots are arranged in a parallel - flow pattern. The facing sheet can be made of, for example, the same material as the slotted sheet or can be made of a different material. The facing sheet is typically not slotted, but can be slotted in some structures. The facing sheet can have filtering properties or can be a non - filtering material (such as a spacer material) that does not have filtering properties. Additionally, the facing sheet can cover all or only a portion of each slotted sheet. The facing sheet can be continuous or segmented such that separate facing sheet segments are positioned against each slotted sheet.

[0073] The different media types in the multiple slots are in parallel flow with each other. As described above, as used herein, the term "parallel" refers to a configuration in which the fluid flow to be filtered is dispersed into a first plurality of slots and a second plurality of slots and then typically converges again. Thus, "parallel" does not require that the slots themselves be arranged in a geometrically parallel configuration (although they often are), but rather that the plurality of slots have a generally parallel flow relative to each other. Thus, "parallel" flow is contrasted with "serial" flow, where the flow comes from the first plurality of slots and then enters the second plurality of slots. It should be understood that in some configurations, such as a wrap structure, the fluid flow can be between adjacent portions of the filter medium.

[0074] Moreover, it will be understood that the parallel flow can include media elements where, as long as there is parallel flow, the first plurality of slots and the second plurality of slots have the same slot length or have different slot lengths. Similarly, the first plurality of slots and the second plurality of slots can have a single front and a single back, can have fronts and backs that are flush with each other, or can have fronts and backs that are offset from each other. In some configurations, the first plurality of slots and the second plurality of slots are separated from each other but still in parallel flow and thus act as a single element.

[0075] The media can be arranged in the media element in various configurations, including alternating single layers (e.g., the structure A / B / C / A / B / C..., where A, B, and C each refer to a different slot type, and " / " indicates a separate layer. Thus, A / B / C / A / B / C.... refers to a slotted medium having a first layer of slots with structure A, followed by a second layer of slots with structure B, and a third layer of slots with structure C. This order is repeated for the fourth, fifth, and sixth layers in the A / B / C / A / B / C arrangement. This A / B / C arrangement can be repeated multiple times to create a complete media element.

[0076] The use of the terms "A", "B", and "C" slots is meant to represent media having different characteristics. For example, the A-type slots can have a greater height than the B-type or C-type slots; or the B-type slots can have a greater or smaller width than the A-type or C-type slots; or the A-type slots can be formed of a medium having a higher efficiency and / or permeability than the B-type or C-type slots.

[0077] It should also be understood that the media can be arranged in a configuration where similar-slot layers are grouped together, such as a media element having the structure A / A / A / A / B / B / B / C / C / C. In this structure, there are four layers with A slots, three layers with B slots, and three layers with C slots. Each of the layers of the types of slots A, B, and C is grouped together. Different media regions containing different types of slots can be in direct contact with each other, such as by being arranged in a stacked or wrap configuration. They are also arranged such that the different media regions are separated by dividers or other components.

[0078] It will also be understood that depending on the slot size, media element size, etc., more than three or four similar slots can be grouped together. The media element can be constructed with multiple layers of each media, such as (for example) ten, twenty, thirty, or forty layers of grouped slot A; or ten, twenty, thirty, or forty layers of grouped slot B, etc.

[0079] In some configurations, the slots can vary repeatedly within a layer as well as between layers. For example, a media element having the structure ABC... / DEF... / ABC... / DEF... / ABC... / DEF... causes layers having repeating slots A, B, and C to alternate with layers having slots D, E, and F. Other examples are not limited to including media elements having AB.... / CDEF... / AB... / CDEF; media elements having A... / BCD... / A... / BCD....

[0080] Using more than one slot configuration within a given filter media element or air cleaner can provide various benefits, including the lower initial restriction of one slot configuration and the dust holding capacity of a second slot configuration. Thus, an element formed from a combination of media can outperform an element formed from only one slot configuration. Combining different types and styles of slot geometries in this way allows for improvement in one or more of cost, initial pressure drop, load capacity, or other aspects of filtration performance.

[0081] In some configurations, the relative position of the media is determined by the desired element characteristics. For example, due to the air cleaner in which the filter element is placed, a higher permeability media can be arranged in the region of the filter element having the highest face velocity to reduce the initial restriction. In other embodiments, a higher efficiency media is arranged in the region having the highest face velocity to increase the initial efficiency of the filter element.

[0082] This summary of the invention is a general overview of some of the teachings of the present application and is not intended to be an exclusive or exhaustive treatment of the subject matter. Further details can be found in the detailed description and the appended claims. After reading and understanding the following detailed description and viewing the drawings that form a part of the detailed description, other aspects will be apparent to those of ordinary skill in the art, and these should not be construed in a limiting sense. The scope of the present application is defined by the appended claims and their legal equivalents. BRIEF DESCRIPTION OF THE DRAWINGS

[0083] Various aspects can be more fully understood in conjunction with the following drawings, in which:

[0084] Figure 1 is a perspective view of an exemplary filter element in accordance with an exemplary embodiment.

[0085] Figure 2AIt is an enlarged schematic cross-sectional view of the cross-section of the filter medium.

[0086] Figure 2B It is a partially enlarged cross-sectional view of a slotted medium and top and bottom facing sheets.

[0087] Figures 3A to 3F It is a schematic representation of the component performance (these figures are illustrative and not based on test data from actual measurements)

[0088] Figure 4A It is a top schematic view of an exemplary filter medium element, showing a wound configuration with two types of filter media.

[0089] Figure 4B It is a top schematic view of an exemplary filter medium element, showing a wound configuration with three types of filter media.

[0090] Figure 5 It is a top schematic view of an exemplary filter medium element, showing a stacked configuration of the filter media.

[0091] Figure 6 It is a top schematic view of an exemplary filter medium element, showing a stacked configuration of the filter media.

[0092] Figure 7 It is a top schematic view of an exemplary filter medium element, showing a stacked configuration of the filter media.

[0093] Figure 8 It is a top schematic view of an exemplary filter medium element, showing a stacked configuration with three types of filter media.

[0094] Figure 9 It is a top schematic view of an exemplary filter medium element, showing a stacked configuration with two types of filter media.

[0095] Figure 10 It is a top schematic view of an exemplary filter medium element, showing a stacked configuration with two types of filter media.

[0096] Figure 11 It is a top schematic view of an exemplary filter medium element, showing a stacked configuration with two types of filter media.

[0097] Figure 12 It is a top schematic view of an exemplary filter medium element, showing a stacked configuration with two types of filter media.

[0098] Figure 13 It is a top schematic view of an exemplary filter medium element, showing a stacked configuration with two types of filter media.

[0099] Figure 14 Is a top view of an exemplary filter media element, showing a stacked configuration with three types of filter media.

[0100] Figure 15 Is a top view of an exemplary filter media element, showing a wound configuration with two types of filter media.

[0101] Figure 16 Is a top view of an exemplary filter media element, showing a wound configuration with three types of filter media.

[0102] Figure 17 Is a top view of an exemplary filter media element, showing a stacked configuration with three types of filter media.

[0103] Figure 18 Is a top view of an exemplary filter media element, showing a stacked configuration with two types of filter media.

[0104] Figure 19 Is a top view of an exemplary filter media element, showing a stacked configuration with two types of filter media.

[0105] Figure 20 Is a top view of an exemplary filter media element, showing a stacked configuration with two types of filter media.

[0106] Figure 21 Is a top view of an exemplary filter media element, showing a stacked configuration with two types of filter media.

[0107] Figure 22 Is a top view of an exemplary filter media element, showing a stacked configuration with two types of filter media.

[0108] Figure 23 Is a top view of an exemplary filter media element, showing a stacked configuration with three types of filter media.

[0109] Figure 24A Is a top view of an exemplary filter media element, showing a wound configuration with two types of filter media.

[0110] Figure 24B Is a top view of an exemplary filter media element, showing a wound configuration with two types of filter media.

[0111] Figure 25A Is a top view of an exemplary filter media element, showing a wound configuration with three types of filter media.

[0112] Figure 25BIs a top view schematic of an exemplary filter media element, showing a wound configuration with three types of filter media.

[0113] Figure 26A Is a top view schematic of an exemplary filter media element, showing a wound configuration with two types of filter media.

[0114] Figure 26B Is a top view schematic of an exemplary filter media element, showing a wound configuration with two types of filter media.

[0115] Figure 27 Shows the performance results of a comparative test of filter elements with different media types.

[0116] Figure 28A and Figure 28B Shows the performance results of various media structures, including dust loading and pressure drop

[0117] Figure 29A and Figure 29B Shows the performance results of various media structures, including dust loading and pressure drop

[0118] Figure 30A and Figure 30B Shows the performance results of various media structures, including dust loading and pressure drop

[0119] Although the embodiments are susceptible to various modifications and alternative forms, the details thereof have been shown by way of example and will be described in detail. However, it should be understood that the scope herein is not limited to the described embodiments. On the contrary, the invention will cover modifications, equivalents, and alternatives falling within the spirit and scope herein. Detailed Description

[0120] In an exemplary embodiment, the present application relates to an air filter media element comprising a plurality of layers of grooved media, each layer comprising a first plurality of grooves and a second plurality of grooves, the first plurality of grooves and the second plurality of grooves being arranged in a parallel flow configuration; wherein, the first plurality of grooves and the second plurality of grooves exhibit differences in groove shape, groove size, groove height, groove width, groove length, groove cross-sectional area, or filter media. In an exemplary embodiment, the difference is a difference in the taper of the first plurality of grooves and the second plurality of grooves.

[0121] These multiple slots are arranged in a parallel flow configuration. As described above, as used in this context, the term "parallel" refers to a structure in which the fluid flow to be filtered is dispersed into a first plurality of slots and a second plurality of slots and then typically converges again. Thus, "parallel" does not require the slots themselves to be arranged in a geometrically parallel configuration (although they often are), but rather the plurality of slots present a parallel flow relative to each other. Thus, "parallel" flow is contrasted with "serial" flow (wherein in serial flow, the flow comes from a first plurality of slots and then enters a second plurality of slots).

[0122] In some implementations, the filter media element can be constructed such that the first plurality of slots and the second plurality of slots are arranged together within at least one layer of slotted media. In other implementations, the first plurality of slots are arranged in a first plurality of layers, and the second plurality of slots are arranged in a second plurality of layers of slotted media. These two structures can also be combined such that the individual layers have a repeating difference between the slots and the different layers are combined.

[0123] An exemplary embodiment is an air filter element for removing particulates from an air stream, the air filter element comprising:

[0124] a) a first plurality of slots; and

[0125] b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of slots presenting a difference from the first plurality of slots in slot shape, slot size, slot height, slot width, slot length, slot cross-sectional area, or filter media;

[0126] wherein the first plurality of slots and the second plurality of slots have a common upstream face and a common downstream face; and

[0127] wherein when the filter element is loaded with dust at a substantially constant velocity, the first plurality of slots and the second plurality of slots perform as follows:

[0128] a) The first plurality of slots and the second plurality of slots have substantially equal initial pressure drops from the upstream face to the downstream face;

[0129] b) The initial velocity of the first plurality of slots is greater than the initial velocity of the second plurality of slots;

[0130] c) During dust loading:

[0131] i) When the velocities of the first plurality of slots and the second plurality of slots change relative to each other, the pressure drops across the first plurality of slots and the second plurality of slots remain substantially equal relative to each other; and

[0132] ii) The velocity across the first plurality of slots decreases, and the velocity across the second plurality of slots increases, at least until the velocity across the second plurality of slots is greater than the velocity across the first plurality of slots.

[0133] In an embodiment, the transition from a speed of the first plurality of slots being greater than a speed of the second plurality of slots to a speed of the second plurality of slots being greater than a speed of the first plurality of slots occurs before the media element is loaded to 10% of its dust loading capacity.

[0134] In an embodiment, the transition from a speed of the first plurality of slots being greater than a speed of the second plurality of slots to a speed of the second plurality of slots being greater than a speed of the first plurality of slots occurs before the media element is loaded to 15% of its dust loading capacity.

[0135] In an embodiment, the transition from a speed of the first plurality of slots being greater than a speed of the second plurality of slots to a speed of the second plurality of slots being greater than a speed of the first plurality of slots occurs before the media element is loaded to 20% of its dust loading capacity.

[0136] In an exemplary implementation, two different media elements are combined into a single filter element, and the two media elements have different pressure drop and loading characteristics. In an example, the first media element has a lower initial pressure drop than the second media element, while the second media element has a greater dust holding capacity than the first media element. In certain configurations, the combination of the two media results in an element that has better performance than that achieved with either media alone and better performance than that achieved by simply averaging the performance of each media element. Thus, the hybrid filter element can (for example) exhibit a reduced initial pressure flow, but also exhibit an increased loading.

[0137] In an exemplary implementation, an air filtration media element for removing particulates from an air stream includes: a first plurality of slots; and a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of slots presenting a difference from the first plurality of slots in slot shape, slot size, slot height, slot width, slot length, slot cross-sectional area, or filtration media. The first plurality of slots and the second plurality of slots have a common upstream face and a common downstream face; and when loading dust at a substantially constant speed, the first plurality of slots and the second plurality of slots perform as follows: a) the first plurality of slots and the second plurality of slots have substantially equal initial pressure drops from the upstream face to the downstream face; b) the initial speed of the first plurality of slots is greater than the initial speed of the second plurality of slots; c) during dust loading: i) the speed through the first plurality of slots decreases, and the speed through the second plurality of slots increases, at least until the speed through the second plurality of slots is greater than the speed through the first plurality of slots; and ii) when the speeds of the first plurality of slots and the second plurality of slots change relative to each other, the pressure drops across the first plurality of slots and the second plurality of slots remain substantially equal relative to each other.

[0138] Velocity is volumetric flow rate / element volume. Example ranges of velocity are, for example, from 300 to 3000 cfm / cubic foot. In some implementations, the velocity range is from 500 to 2000 cfm / cubic foot. In certain embodiments, the velocity is greater than 300 cfm / cubic foot, greater than 500 cfm / cubic foot, greater than 1000 cfm / cubic foot, or greater than 2000 cfm / cubic foot. In certain embodiments, the velocity is less than 3000 cfm / cubic foot, less than 2000 cfm / cubic foot, less than 1000 cfm / cubic foot, or less than 500 cfm / cubic foot.

[0139] The flow rate through the element can be, for example, 200 to 3000 cubic feet per minute (cfm). In some implementations, the flow rate is greater than 200 cfm, greater than 500 cfm, greater than 1000 cfm, greater than 1500 cfm, greater than 2000 cfm or greater than 2500 cfm. In some implementations, the flow rate is less than 3000 cfm, less than 2500 cfm, less than 2000 cfm, less than 1500 cfm, less than 1000 cfm or less than 500 cfm.

[0140] The restriction at the element terminal can be, for example, 10 to 40 inches of water. In some implementations, the restriction at the terminal is greater than 10 inches of water, greater than 15 inches of water, greater than 20 inches of water, greater than 25 inches of water, greater than 30 inches of water or greater than 35 inches of water. In some implementations, the restriction at the terminal is less than 40 inches of water, less than 35 inches of water, less than 30 inches of water, less than 25 inches of water, less than 20 inches of water or less than 15 inches of water.

[0141] The rise in restriction to the terminal can be, for example, 5 to 35 inches of water. In some implementations, the rise in restriction to the terminal can be greater than 5 inches of water, greater than 10 inches of water, greater than 15 inches of water, greater than 20 inches of water, greater than 25 inches of water, greater than 30 inches of water or greater than 35 inches of water. In some implementations, the rise in restriction to the terminal is less than 40 inches of water, less than 35 inches of water, less than 30 inches of water, less than 25 inches of water, less than 20 inches of water or less than 15 inches of water.

[0142] In an exemplary structure, the first media element can be, for example, about 20%, 30%, 40% or 50% of the media element (measured by the volume of the package); and the second media element can be, for example, about 20%, 30%, 40% or 50% of the media element (measured by the volume of the package). As used herein, the volume of the package means the total volume occupied by the media element when measuring the area contained within the perimeter of the package. Thus, the volume of the package can include the media itself, as well as the open volume into which dust can be loaded.

[0143] In such exemplary structures, the first media element can be, for example, about 20%, 30%, 40%, or 50% of the media element (measured by media surface area); and the second media element can be, for example, about 20%, 30%, 40%, or 50% of the media element (measured by media surface area). As used herein, the wrap surface area means the total surface area of the media in each media element in the case where the media element is disassembled and the media is unrolled.

[0144] In some implementations, the first plurality of slots constitute 10% to 90% of the inlet face of the media element, and the second plurality of slots constitute 90% to 10% of the inlet face of the media element. Alternatively, the first plurality of slots constitute 20% to 40% of the inlet face of the media element, and the second plurality of slots constitute 60% to 80% of the inlet face of the media element. In other implementations, the first plurality of slots constitute 40% to 60% of the inlet face of the media element, and the second plurality of slots constitute 60% to 40% of the inlet face of the media element. In yet another implementation, the first plurality of slots constitute 60% to 90% of the inlet face of the media element, and the second plurality of slots constitute 40% to 10% of the inlet face of the media element.

[0145] Another embodiment of the filter media element includes a third plurality of slots arranged in a parallel flow arrangement with the first plurality of slots and the second plurality of slots; wherein the first plurality of slots, the second plurality of slots, and the third plurality of slots exhibit regularly repeating differences in slot shape, slot size, slot height, slot width, slot cross-sectional area, or filter media. Optionally, each of the first plurality of slots, the second plurality of slots, and the third plurality of slots is arranged in a separate plurality of layers. It should be understood that in some implementations, more than three pluralities of slots are arranged in a parallel flow arrangement, wherein each of the pluralities of slots exhibits regularly repeating differences in slot shape, slot size, slot height, slot width, slot cross-sectional area, or filter media.

[0146] In an exemplary structure having three types of slots, the first slot, the second slot, and the third slot can be selected such that the first plurality of slots constitute 30% to 50% of the inlet face of the media element; the second plurality of slots constitute 20% to 40% of the inlet face of the media element; and the third plurality of slots constitute 20% to 40% of the inlet face of the media element.

[0147] In another exemplary structure having three types of slots, the first slot, the second slot, and the third slot can be selected such that the first plurality of slots constitute 50% to 70% of the inlet face of the media element; the second plurality of slots constitute 10% to 30% of the inlet face of the media element; and the third plurality of slots constitute 10% to 30% of the inlet face of the media element.

[0148] In some implementations, the multi-layer single-sided media is arranged in a wound configuration, while in other implementations, the sided media is arranged in a stacked configuration.

[0149] In some configurations, the first multi-layer single facer medium and the second multi-layer single facer medium are arranged in a hybrid configuration, where one or more of the first plurality of single facer media are alternated with one or more of the second plurality of single facer media. In an exemplary implementation having at least three types of single facer media, the first multi-layer single facer medium and the second multi-layer single facer medium are arranged in a hybrid configuration, where one or more of the first plurality of single facer media are alternated with one or more of the second plurality of single facer media and one or more of the third plurality of single facer media. Additionally, when three types of media are used, the first multi-layer single facer medium, the second multi-layer single facer medium, and the third multi-layer single facer medium are arranged in a hybrid configuration, where one or more of the first plurality of single facer media are alternated with one or more of the second plurality of single facer media and one or more of the third plurality of single facer media. In some implementations, more than three types of filter media are used, and these different types of media can be combined in a hybrid manner or in an aggregated manner, where the different types of media are collected together without mixing between the media types. Alternatively, the media can be aggregated into smaller groups and then mixed, such as by having one type of media with five layers and a different media with three layers.

[0150] Referring now to the drawings, other aspects of the filter media, media elements, and elements will be identified.

[0151] First, with respect to Figure 1 , a perspective view of an exemplary filter element 10 is shown. The exemplary filter element 10 includes an inlet 12, an outlet 14 on the side of the element 10 opposite the inlet 12, and a wound z-flow medium 20 within the element 10. A seal surrounding the inlet 12 is shown, and a support frame 40 is depicted. It should also be understood that the filter element can have a flow opposite to that shown in Figure 1 , such that the inlet 12 and the outlet 14 are reversed.

[0152] Figure 2A is an enlarged schematic cross-sectional view of a cross-section of a single facer filter medium 200 suitable for use in a filter media element and a filter element as described herein. The single facer medium 200 includes a slotted sheet 210, as well as a top facer sheet 220 and a bottom facer sheet 230. The slotted sheet 210 includes a plurality of slots 250. A fluid stream to be filtered (such as air for an internal combustion engine) enters the slots 250 along a flow path 260 and then travels along the slots until it passes through the filter media and exits different slots along a fluid flow path 270. For example, such a fluid flow through a slotted media element is described in U.S. Patent No. 7,99,702 to Rocklitz, which is incorporated herein by reference in its entirety.

[0153] Figure 2BA front view of a grooved media constructed and arranged in accordance with an embodiment of the present invention, the grooved media having a grooved sheet 280, a top facing sheet 282, and a facing media 284, showing the dimensions of an example groove. The grooved sheet 280 includes a groove 281. In the depicted embodiment, the groove 281 has a width A measured from a first peak to an adjacent peak. In an exemplary embodiment, the width A is from 0.75 to 0.125 inches, optionally from 0.5 to 0.25 inches, and optionally from 0.45 to 0.3 inches. The groove 281 also has a height B measured from adjacent peaks of the same size. The groove 281 has an area measured perpendicular to the groove length between the grooved sheet 281 and the facing sheet 282. When the height, width, or shape of the groove varies along its length, such as when the groove tapers, the area may vary according to the length of the groove.

[0154] In an exemplary embodiment, an air filtration element for removing particulate matter from an air stream includes: a) a first plurality of grooves; and b) a second plurality of grooves arranged in a parallel flow configuration with the first plurality of grooves; the second plurality of grooves presenting a difference from the first plurality of grooves in groove shape, groove size, groove height, groove width, groove length, groove cross-sectional area, or filtration medium; wherein the first plurality of grooves and the second plurality of grooves have a common upstream face and a common downstream face; and wherein, when the filtration element is loaded with dust at a substantially constant velocity, the first plurality of grooves and the second plurality of grooves perform as follows:

[0155] a) The first plurality of grooves and the second plurality of grooves have a substantially equal initial pressure drop from the upstream face to the downstream face;

[0156] b) The initial velocity of the first plurality of grooves is greater than the initial velocity of the second plurality of grooves;

[0157] c) During dust loading, as Figure 3A shown:

[0158] i) When the velocities of the first plurality of grooves and the second plurality of grooves vary relative to each other, the pressure drops across the first plurality of grooves and the second plurality of grooves remain substantially equal relative to each other; and

[0159] ii) The velocity across the first plurality of grooves decreases, and the velocity across the second plurality of grooves increases, at least until the velocity across the second plurality of grooves is greater than the velocity across the first plurality of grooves.

[0160] These properties are shown, for example, in Figure 3A which is a schematic representation of the variation of flow rate in the element (the figure is illustrative and not based on test data from actual measurements).

[0161] In an exemplary implementation, an air filtration media element for removing particulates from an air stream includes: a) a first plurality of channels; and b) a second plurality of channels arranged in a parallel flow configuration with the first plurality of channels; the second plurality of channels exhibit differences from the first plurality of channels in terms of channel shape, channel size, channel height, channel width, channel cross-sectional area, channel length, or filtration media; wherein the first plurality of channels and the second plurality of channels have a common upstream face and a common downstream face. When the filtration element is loaded with dust, the first plurality of channels and the second plurality of channels will perform as follows:

[0162] a) When the first plurality of channels and the second plurality of channels are independently tested at the same media element velocity, the first plurality of channels have an initial pressure drop ΔP 2,i lower than the initial pressure drop ΔP 1,i across the second plurality of channels; and the initial slope Δ(ΔP 1,i / L 1,i ) a of the pressure drop / loading curve of the first plurality of channels at time a is greater than the initial slope Δ(ΔP 2,i / L 2,i ) a of the second plurality of channels:

[0163] Δ(ΔP 1,i / L 1,i ) a > Δ(ΔP 2,i / L 2,i ) a

[0164] b) When the first plurality of channels and the second plurality of channels are combined and tested simultaneously in parallel flow, the initial velocity V 1,a of the first plurality of channels at time a is greater than the initial velocity V 2,a of the second plurality of channels at time a:

[0165] V 1,a > V 2,a

[0166] c) When the first plurality of channels and the second plurality of channels are combined and tested simultaneously in parallel flow, the intermediate second velocity V 1,b of the first plurality of channels at a subsequent time b is equal to the intermediate velocity V 2,b of the second plurality of channels:

[0167] V 1,b = V 2,b

[0168] d) When the first plurality of channels and the second plurality of channels are combined and tested simultaneously in parallel flow, the third velocity V1,c a third velocity V that is less than the second plurality of slots 2,c :

[0169] V 1,c < V 2,c

[0170] These properties are shown, for example, in Figure 3B and Figure 3C These figures are schematic representations of the component performance (these figures are representative and not based on test data from actual measurements).

[0171] In an exemplary implementation, an air filtration element for removing particulates from an air stream includes: a) a first plurality of slots; and b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of slots exhibit differences from the first plurality of slots in slot shape, slot size, slot height, slot width, slot cross-sectional area, slot length, or filter medium; wherein the first plurality of slots and the second plurality of slots have a common upstream face and a common downstream face. When simultaneously loading dust under parallel flow conditions and when the loading reaches such that the pressure drop of the media element is at least 10 inches of water, the first plurality of slots and the second plurality of slots perform as follows:

[0172] a) The time-averaged velocity of the first plurality of slots is less than the time-averaged velocity of the entire filter element , and the time-averaged velocity of the second plurality of slots is greater than the time-averaged velocity of the filter element

[0173]

[0174]

[0175] b) The load change ΔL1 of the first plurality of slots is equal to the load of the first plurality of slots tested at the time-averaged velocity L of the first plurality of slots 1,(V1 avg) minus the load of the first plurality of slots tested at the time-averaged velocity L of the element: 1,(V元件avg) 1,(V1

[0176] ΔL1 = L avg) 1,(V元件avg) - L 2,(V2

[0177] ΔL1 > 0

[0178] c) The load change ΔL2 of the second plurality of slots is equal to the load of the second plurality of slots tested at the time-averaged velocity L of the second plurality of slots 2,(V2 avg)The load of the second plurality of slots measured below minus the component time-averaged velocity L 2,(V元件avg) The load of the second plurality of slots measured below:

[0179] ΔL2 = L 2,(V2 avg) -L 2,(V元件avg)

[0180] ΔL2 < 0

[0181] d) The sum of ΔL1 and ΔL2 is greater than 0:

[0182] ΔL1 + ΔL2 > 0

[0183] These properties are shown, for example, in Figure 3D and Figure 3E These figures are schematic representations of the component performance (these figures are representative and not based on test data from actual measurements).

[0184] In an exemplary implementation, a filter media element for removing particulates from an air stream includes: a) a first plurality of slots; and b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of slots exhibit differences from the first plurality of slots in slot shape, slot size, slot height, slot width, slot length, slot cross-sectional area, or filter media; wherein the first plurality of slots and the second plurality of slots have a common upstream face and a common downstream face; and wherein the first plurality of slots and the second plurality of slots perform as follows:

[0185] i) The pressure drop ΔP increases as the flow rate Q increases;

[0186] ii) Before loading, when the first plurality of slots and the second plurality of slots are tested independently and at the same velocity, the first plurality of slots have an initial pressure drop ΔP 2,0 lower than the initial pressure drop ΔP across the second plurality of slots 1,0 ;

[0187] ΔP 1,0 < ΔP 2,0

[0188] iii) When tested in parallel, the velocity of the first plurality of slots before loading is greater than the average air filter element velocity before loading, and the velocity of the second plurality of slots before loading is less than the average air filter media element velocity before loading;

[0189] V 1,0 > V (元件平均),0

[0190] V 2,0 < V (元件平均),0

[0191] v) When the tests are carried out in parallel, the pressure drop difference Δ(ΔP1) is equal to the pressure drop of the first plurality of slots before the load measured at the first plurality of slot velocities ΔP 1,0,(V1,0) minus the pressure drop of the first plurality of slots before the load measured at the filter element average velocity ΔP 1,0,(V元件avg,0) :

[0192] Δ(ΔP1) = ΔP 1,0,(V1,0) - ΔP 1,0,(V元件avg,0)

[0193] v) When the tests are carried out in parallel, the pressure drop difference Δ(ΔP2) of the second plurality of slots is equal to the pressure drop of the second plurality of slots before the load measured at the second plurality of slot velocities ΔP 2,0,(V2,0) minus the pressure drop of the second plurality of slots before the load measured at the filter element average velocity ΔP 2,0,(V元件avg,0) :

[0194] Δ(ΔP2) = ΔP 2,0,(V2,0) - ΔP 2,0,(V元件avg,0)

[0195] d) The sum of Δ(ΔP1) and Δ(ΔP2) is less than 0:

[0196] Δ(ΔP1) + Δ(ΔP2) < 0.

[0197] These properties are shown, for example, in Figure 3F which is a schematic representation of the performance (the figure is illustrative and not based on test data from actual measurements).

[0198] Figure 4A is a top schematic view of an exemplary filter media element 300 for a filter element. The filter media element 300 has two types of filter media: a first media 310 and a second media 320. The media are shown in a wound configuration where the two types of filter media are mixed and overlapped. The filter media 310 and 320 are shown schematically without showing the actual slots of the media. The filter media element 300 can typically be formed by simultaneously winding different types of media around a central axis. In this exemplary embodiment, the ratio of the surface area of media 310 to 320 is approximately 1:1.

[0199] Figure 4Bis a top view schematic of an exemplary filter media element 400, showing a wound configuration with three types of filter media. The filter media element 400 has three types of filter media: a first media 410, a second media 420, and a third media 430. The media is shown in a wound configuration where the three types of filter media are mixed and overlapped. The filter media 410, 420, and 430 are shown in schematic form without showing the actual slots of the media. The filter media element 430 can typically be formed by simultaneously winding three different types of media around a central axis. In this exemplary embodiment, the ratio of the surface areas of media 410 to 420 to 430 is approximately 1:1:1.

[0200] Figure 5 is a top view schematic of an exemplary filter media element 500, showing a stacked configuration with two types of slots. The filter media element 500 has two types of slots: a first slot 510 and a second slot 520.

[0201] Figure 6 is a top view schematic of an exemplary filter media element 600, showing a stacked configuration with different types of filter media. The filter media element 600 has three types of slots: a first slot 610, a second slot 620, and a third slot 630.

[0202] Figure 7 is a top view schematic of an exemplary filter media element 700, showing a stacked configuration with different types of slots. The filter media element 710 has two types of slots: a first slot 710 and a second slot 720. Figure 8 is a top view schematic of an exemplary filter media element 800, showing a stacked configuration with three types of filter media. The three types of filter media are a first media 810, a second media 820, and a third media 830. The media is shown in a stacked configuration where the three types of filter media are separated by media type and not mixed. In this exemplary embodiment, based on the package entry area, the ratio of filter media 810 to 820 to 830 is approximately 4:3:3. Figure 9 is a top view schematic of an exemplary filter media element 900, showing a stacked configuration with two types of filter media: a first media 910 and a second media 920. The media is shown in a stacked configuration where the two types of filter media are separated and not mixed. In this exemplary embodiment, based on the total package entry area, the ratio of filter media 910 to 920 is approximately 1:1. Figure 10 is a top view schematic of an exemplary filter media element 1000, showing a stacked configuration with two types of filter media: a first media 1010 and a second media 1020. The media is shown in a stacked configuration. In this exemplary embodiment, based on the total package entry area, the ratio of filter media 1010 to 1020 is approximately 9:1.

[0203] Figure 11 is a top view of an exemplary filter media element, showing a stacked configuration with two types of filter media. The filter media element 1100 has two types of filter media: a first media 1110 and a second media 1120. The media 1110 and 1120 are stacked such that five layers of the filter media 1110 alternate with two layers of the media 1120. Figure 12 is a top view of an exemplary filter media element, showing a stacked configuration with two types of filter media. The filter media element 1200 has two types of filter media: a first media 1210 and a second media 1220. The media are shown in a stacked configuration. The media 1210 and 1220 are stacked such that two layers of the filter media 1210 alternate with one layer of the media 1220. Figure 13 is a top view of an exemplary filter media element 1300, showing a stacked configuration with two types of filter media. The filter media element 1300 has two types of filter media: a first media 1310 and a second media 1320. The media 1310 and 1320 are stacked where one layer of the filter media 1310 alternates with one layer of the media 1320. Figure 14 is a top view of an exemplary filter media element 1400. The filter media element 1400 has three types of filter media: a first media 1410, a second media 1420, and a third media 1430. The media layers 1410, 1420, and 1430 are in an alternating stacked arrangement. Figure 15 is a top view of an exemplary filter media element 1500, showing a wound configuration with two types of filter media 1510 and 1520. The media are wound such that the first media 1510 is on the inside and the second media 1520 is on the outside, and the first media 1510 and the second media 1520 are spliced together.

[0204] Figure 16 is a top view of an exemplary filter media element 1600, showing a wound configuration with three types of filter media 1610, 1620, and 1630. The media are wound such that the first media 1610 is on the inside, the second media 1620 is in the middle, and the third media 1630 is on the outside. The first media 1610 and the second media 1620 are spliced together, and the second media 1620 and the third media 1630 are spliced together.

[0205] Figure 17is a schematic top view of an exemplary filter media element 1700, showing a stacked configuration with three types of filter media. The three types of filter media are a first media 1710, a second media 1720, and a third media 1730. The media are shown in a stacked configuration where the three types of filter media are separated by media type and not mixed. In this exemplary embodiment, based on the total package inlet area, the ratio of filter media 1710 to 1720 to 1730 is approximately 4:3:3.

[0206] Figure 18 is a schematic top view of an exemplary filter media element 1800, showing a stacked configuration with two types of filter media: a first media 1810 and a second media 1820. The media are shown in a stacked configuration where the two types of filter media are separated. In this exemplary embodiment, based on the total package inlet area, the ratio of filter media 1810 to 1820 is approximately 1:1.

[0207] Figure 19 is a schematic top view of an exemplary filter media element 1900, showing a stacked configuration with two types of filter media. The filter media element 1900 has two types of filter media: a first media 1910 and a second media 1920. The media are shown in a stacked configuration. In this exemplary embodiment, based on the total package inlet area, the ratio of filter media 1910 to 1920 is approximately 9:1.

[0208] Figure 20 is a schematic top view of an exemplary filter media element 2000, showing a stacked configuration with two types of filter media. The filter media element 2000 has two types of filter media: a first media 2010 and a second media 2020. The media element 2000 has six layers of filter media 2010 alternating with two layers of media 2020.

[0209] Figure 21 is a schematic top view of an exemplary filter media element 2100, showing a stacked configuration with two types of filter media. The filter media element 2100 has two types of filter media: a first media 2110 and a second media 2120. The media element 2100 has two layers of filter media 2110 alternating with one layer of media 2120.

[0210] Figure 22 is a schematic top view of an exemplary filter media element 2200, showing a stacked configuration with two types of filter media. The two types of filter media are a first media 2210 and a second media 2220. The media are shown in a stacked configuration where the two types of filter media are mixed.

[0211] Figure 23is a schematic top view of an exemplary filter media element 2300, showing a stacked configuration having three types of filter media. The three types of filter media are a first media 2310, a second media 2320, and a third media 2330. The media are shown in a stacked configuration where the three types of filter media are mixed.

[0212] Figure 24A is a schematic top view of an exemplary filter media element 2400, showing a wound configuration having two types of filter media: a first media 2410 and a second media 2420. The media are shown in a wound configuration where the two types of media are differentiated from each other by first laying the filter media 2420 and then secondly laying the filter media 2420. In this exemplary embodiment, the ratio of the package entry area 2420 to 2410 is approximately 2:1. This structure can be created by, for example, winding a first single-sided media type over a period of time; cutting the roll and splicing a second single-sided media type to the end region of the first single-sided media type; continuing the winding process; and repeating for as many single-sided media types as needed. Alternatively, the winding of each single-sided media type can be done separately, and as a secondary process the parts can be put together and sealed.

[0213] Figure 24B is a schematic top view of an exemplary filter media element 2450, showing a wound configuration having two types of slots forming the filter media. The filter media element has two types of slots: a first media 2460 and a second media 2470. The media are shown in a wound configuration where the two types of slots are separated from each other. In this exemplary embodiment, the ratio of the package entry area 2470 to 2460 is approximately 2:1.

[0214] Figure 25A is a schematic top view of an exemplary filter media element 2500, showing a wound configuration having three types of filter media: a first media 2510, a second media 2520, and a third media 2530. The media are shown in a wound configuration where the media are separated from each other by first laying the filter media 2520, and then laying the second media 2520 on top of the media 2510, and laying the third media 2530 on top of the media 2520. In this exemplary embodiment, the ratio of the package entry area 2510 to 2520 to 2530 is approximately 4:3:3.

[0215] Figure 25BIs a top view schematic of an exemplary filter media element 2550, showing a wound configuration with three types of filter media. The filter media element 2550 has a first media 2560, a second media 2570, and a third media 2580. The media is shown in a wound configuration, where the three types of media are separated from each other. In this exemplary embodiment, the ratio of the pack entry areas 2560 to 2570 to 2580 is approximately 4:3:3.

[0216] Figure 26A Is a top view schematic of an exemplary filter media element 2600, showing a wound configuration with two types of filter media. The filter media element 2600 has two types of filter media: a first media 2610 and a second media 2620. The media is shown in a wound configuration, where the two types of media are separated from each other by first laying the filter media 2620 and then laying the filter media 2620 on top of the media 2610. In this exemplary embodiment, the ratio of the pack entry areas 2610 to 2620 is approximately 1:1.

[0217] Figure 26B Is a top view schematic of an exemplary filter media element 2650, showing a wound configuration with two types of filter media. The filter media element has two types of filter media: a first media 2660 and a second media 2670. The media is shown in a wound configuration, where the two types of media are separated from each other. In this exemplary embodiment, the ratio of the pack entry areas 2660 to 2670 is approximately 1:1.

[0218] Aspects can be better understood with reference to the following examples, where element A, element B, and element C are compared to each other. Element A consists entirely of media A with slots that have a width of approximately 10.7 millimeters and a height of 3.2 millimeters and a tapered cross-sectional area. Element B consists entirely of media B with slots that have a width of approximately 8.0 millimeters and a height of approximately 2.7 millimeters and a tapered area. The slot density per square centimeter of element A is approximately 2.8, and for element B it is approximately 4.4. Element C consists of 50% by volume of media A and 50% by volume of media B to form a mixed media. Figure 27 Shows the loading curves of filter elements made using media A, media B, and the mixed media. The loading curves show the pressure drop of the filter elements as the grams of dust increase from zero to less than 500 grams. As Figure 27As shown, Media B and the mixed media start at very similar levels of restriction (approximately 2.5 inches H20), while Media A has a higher initial pressure drop of approximately 3.2 inches H20. As dust begins to load, the pressure drop across all elements increases, however the pressure drop for Media A and the mixed media increases more slowly than for Media B, where the pressure drops for Media A and Media B cross over (or are the same) at approximately 125 grams of dust. Thus, the mixed media closely tracks Media B when dust loading just begins, and then closely tracks Media A as dust loading increases to higher levels. In other words, the mixed media has an initial pressure drop similar to Media B, but loads similarly to Media A.

[0219] In order to further test the improved filtration performance, a test bench is set up, which has a dual duct system with 5 to 9 cubic meters of air flow per minute, and the dual duct system is configured to measure the pressure drop and the outlet restriction value. The relative performance of the media element formed by the combination of filter media is studied by constructing various filter element designs. These elements are formed by z-flow media arranged in a stacked configuration. These elements each have an inlet face of 150 times 150 mm and an outlet face of 150 times 150 mm, and a depth of 150 mm. The filter element is made of two types of media: media A and media B. The media tank structure of media A and media B is consistent with those shown in U.S. Patent No. 9,623,362 entitled Filtration Media Pack, Filter Elements, and Air Filtration Media, which is granted to inventor Scott M. Brown and transferred to Donaldson Company, Inc.. Media A and B are mainly cellulose media. Media A has a slot height of about 0.092 inches, a slot width of about 0.314 inches, and a slot length (including slot plugs) of about 150 millimeters. Media B has a slot height of about 0.140 inches, a slot width of about 0.430 inches, and a slot length (including slot plugs) of about 150 millimeters. The first type of "segmented" media element is an assembled package of media A and media B positioned adjacent to each other in parallel flow. The second type of "layered" media element includes alternating sheets of media A and media B.

[0220] Figures 28A to 30B Performance results, including dust loading and pressure drop, are shown for various media configurations. Figure 28A , Figure 29A and Figure 30A shows the results of a segmented configuration (media A are grouped together and all media B are grouped together); and Figure 28B , Figure 29B and Figure 30BShows the results of a hierarchical structure (where at least some of the media A and the media layers are mixed). Thus, the media structure includes any of media A, media B, or various volume percentages of media A and media B. The medium represented as 0% on the leftmost side of each graph is without media A and is thus entirely media B. The medium represented as 100% on the rightmost side is only media A and thus without media B. The Y-axis includes the ISO fine dust load measured in grams and the pressure drop measured in inches of water.

[0221] Figure 28A and Figure 28B Show the performance results of various media structures at a cubic flow rate of 5.83 cubic meters per minute, including dust load and pressure drop. From Figure 28A and Figure 28B It can be observed that the best performance, especially the highest dust load, is achieved using a mixed medium: a mixed medium element containing both media A and media B has a higher dust load capacity than media A or media B alone.

[0222] Figure 29A and Figure 29B Show the performance results of various media structures at a cubic flow rate of 7.37 cubic meters per minute, including dust load and pressure drop. Similarly, as Figure 29A and Figure 29B It is the same, the best performance is achieved using a mixed medium of media A and media B.

[0223] Figure 30A and Figure 30B Show the performance results of various media structures at a cubic flow rate of 8.78 cubic meters per minute, including dust load and pressure drop. From Figure 30A and Figure 30B It can be observed that again, the best performance, especially the highest dust load, is achieved using a mixed medium.

[0224] It should be noted that unless the context clearly indicates otherwise, the singular forms "a", "an", and "the" used in this specification and the appended claims include plural referents. Thus, for example, a composition referred to as containing "a compound" includes a mixture of two or more compounds. It should also be noted that unless the context clearly indicates otherwise, the term "or" is generally employed in its sense of including "and / or".

[0225] It should also be noted that as used in this specification and the appended claims, the phrase "configured to" describes a system, device, or other structure that is constructed or configured to perform a particular task or adopt a particular configuration. The phrase "configured to" can be used interchangeably with other similar phrases such as arranged and configured to, constructed and arranged to, constructed to, manufactured and arranged to, etc.

[0226] Aspects have been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications can be made within the spirit and scope of this disclosure.

[0227] The embodiments described herein are not intended to be exhaustive or to limit the invention to the exact forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that those skilled in the art can understand and appreciate the principles and practices.

[0228] All publications and patents mentioned herein are incorporated by reference. The publications and patents disclosed herein are provided only for their disclosure. Nothing herein should be construed as an admission that the inventors are not entitled to antedate any publication and / or patent, including any publication and / or patent cited herein.

Claims

1. An air filtration media element for removing particulates from an air stream, the air filtration media element comprising: a) a first plurality of channels; and b) a second plurality of channels, the second plurality of channels arranged in a parallel flow configuration with the first plurality of channels; the second plurality of channels presenting a difference from the first plurality of channels in terms of channel shape, channel size or channel cross-sectional area; wherein the first plurality of channels and the second plurality of channels have a common upstream face and a common downstream face; and wherein, when the air filtration media element is loaded with dust at a substantially constant velocity, the first plurality of channels and the second plurality of channels perform as follows: a) the first plurality of channels and the second plurality of channels have substantially equal initial pressure drops from the upstream face to the downstream face; b) the initial velocity of the first plurality of channels is greater than the initial velocity of the second plurality of channels; c) during dust loading: i) when the velocities of the first plurality of channels and the second plurality of channels vary relative to each other, the pressure drops across the first plurality of channels and the second plurality of channels remain substantially equal relative to each other; and ii) the velocity across the first plurality of channels decreases and the velocity across the second plurality of channels increases, at least until the velocity across the second plurality of channels is greater than the velocity across the first plurality of channels.

2. The air filtration media element for removing particulate matter from an air stream according to claim 1, wherein, The transition from the velocity of the first plurality of channels being greater than the velocity of the second plurality of channels to the velocity of the second plurality of channels being greater than the velocity of the first plurality of channels occurs before the media element is loaded to 10% of its dust loading capacity.

3. The air filtration medium element for removing particles from an air stream according to any one of claims 1-2, wherein, The transition from the velocity of the first plurality of channels being greater than the velocity of the second plurality of channels to the velocity of the second plurality of channels being greater than the velocity of the first plurality of channels occurs before the media element is loaded to 15% of its dust loading capacity.

4. The air filtration medium element for removing particulate matter from an air stream according to any one of claims 1-2, wherein, The transition from the velocity of the first plurality of channels being greater than the velocity of the second plurality of channels to the velocity of the second plurality of channels being greater than the velocity of the first plurality of channels occurs before the media element is loaded to 20% of its dust loading capacity.

5. The air filtration media element according to any one of claims 1-2, wherein, The first plurality of channels constitute 10% to 90% of the volume of the media element, and the second plurality of channels constitute 90% to 10% of the volume of the media element.

6. The air filtration media element according to any one of claims 1-2, wherein, The first plurality of channels constitute 20% to 40% of the volume of the media element, and the second plurality of channels constitute 60% to 80% of the volume of the media element.

7. The air filtration media element according to any one of claims 1-2, wherein, The first plurality of channels constitute 40% to 60% of the volume of the media element, and the second plurality of channels constitute 60% to 40% of the volume of the media element.

8. The air filtration medium element according to any one of claims 1-2, wherein, The first plurality of channels constitute 10% to 90% of the media surface area of the media element, and the second plurality of channels constitute 90% to 10% of the media surface area of the media element.

9. The air filtration media element according to any one of claims 1-2, wherein, The first plurality of channels constitute 20% to 40% of the media surface area of the media element, and the second plurality of channels constitute 60% to 80% of the media surface area of the media element.

10. The air filtration medium element according to any one of claims 1-2, wherein, The first plurality of channels constitute 40% to 60% of the media surface area of the media element, and the second plurality of channels constitute 60% to 40% of the media surface area of the media element.

11. The air filtration media element according to any one of claims 1-2, wherein, The first plurality of channels constitute 10% to 90% of the inlet face of the media element, and the second plurality of channels constitute 90% to 10% of the inlet face of the media element.

12. The air filtration media element according to any one of claims 1-2, wherein, The first plurality of channels constitute 20% to 40% of the inlet face of the media element, and the second plurality of channels constitute 60% to 80% of the inlet face of the media element.

13. The air filtration media element according to any one of claims 1-2, wherein, The first plurality of slots constitute 40% to 60% of the inlet face of the media element, and the second plurality of slots constitute 60% to 40% of the inlet face of the media element.

14. The air filtration media element according to any one of claims 1 - 2, further comprising a third plurality of slots, the third plurality of slots being arranged in a parallel flow with the first plurality of slots and the second plurality of slots; Among them, The first plurality of slots, the second plurality of slots, and the third plurality of slots exhibit differences in slot shape, slot size, or slot cross - sectional area.

15. The air filtration media element according to claim 14, wherein, Each of the first plurality of slots, the second plurality of slots, and the third plurality of slots is arranged in a separate plurality of layers.

16. The air filtration media element according to any one of claims 1-2, wherein, The multi - layer media element is arranged in a wound configuration or a stacked configuration.

17. The air filtration media element according to any one of claims 1-2, wherein, The differences in slot shape, slot size, or slot cross - sectional area are regular and repetitive.

18. An air filtration media element for removing particulates from an air stream, the air filtration media element comprising: a) a first plurality of slots; and b) a second plurality of slots, the second plurality of slots being arranged in a parallel flow configuration with the first plurality of slots; The second plurality of slots exhibits differences from the first plurality of slots in slot shape, slot size, or slot cross - sectional area; wherein the first plurality of slots and the second plurality of slots have a common upstream face and a common downstream face; wherein when the air filtration media element is loaded with dust, the first plurality of slots and the second plurality of slots perform as follows: a) When the first plurality of slots and the second plurality of slots are independently tested at the same media element speed, the first plurality of slots have a lower initial pressure drop than the initial pressure drop across the second plurality of slots; and the pressure drop ΔP of the first plurality of slots at time a 1,i / load L 1,i The initial slope of the curve Δ(ΔP 1,i / L 1,i ) a is greater than the pressure drop ΔP of the second plurality of slots 2,i / load L 2,i The initial slope of the curve Δ(ΔP 2,i / L 2,i ) a : Δ(ΔP 1,i / L 1,i ) a >Δ(ΔP 2,i / L 2,i ) a b) If the first plurality of slots and the second plurality of slots are combined and tested simultaneously in a parallel flow, the first velocity V of the first plurality of slots at time a 1,a is greater than the first velocity V of the second plurality of slots at time a 2,a : V 1,a >V 2,a c) If the first plurality of slots and the second plurality of slots are combined and tested simultaneously with a parallel flow, the intermediate second velocity V of the first plurality of slots at a subsequent time b 1,b is equal to the intermediate second velocity V of the second plurality of slots 2,b : V 1,b = V 2,b d) If the first plurality of slots and the second plurality of slots are combined and tested simultaneously in a parallel flow, a third velocity V of the first plurality of slots at a subsequent time c 1,c is less than a third velocity V of the second plurality of slots 2,c : V 1,c <V 2,c 。 19. The air filtration media element according to claim 18, wherein, The first plurality of slots constitute 10% to 90% of the volume of the media element, and the second plurality of slots constitute 90% to 10% of the volume of the media element.

20. The air filtration media element according to any one of claims 18-19, wherein, The first plurality of slots constitute 20% to 40% of the volume of the media element, and the second plurality of slots constitute 60% to 80% of the volume of the media element.

21. The air filtration media element according to any one of claims 18-19, wherein, The first plurality of slots constitute 40% to 60% of the volume of the media element, and the second plurality of slots constitute 60% to 40% of the volume of the media element.

22. The air filtration media element according to any one of claims 18-19, wherein, The first plurality of slots constitute 10% to 90% of the media surface area of the media element, and the second plurality of slots constitute 90% to 10% of the media surface area of the media element.

23. The air filtration media element according to any one of claims 18-19, wherein, The first plurality of slots constitute 20% to 40% of the media surface area of the media element, and the second plurality of slots constitute 60% to 80% of the media surface area of the media element.

24. The air filtration media element according to any one of claims 18-19, wherein, The first plurality of slots constitute 40% to 60% of the media surface area of the media element, and the second plurality of slots constitute 60% to 40% of the media surface area of the media element.

25. The air filtration media element according to any one of claims 18-19, wherein The first plurality of slots constitute 10% to 90% of the inlet face of the media element, and the second plurality of slots constitute 90% to 10% of the inlet face of the media element.

26. The air filtration media element according to any one of claims 18-19, wherein, The first plurality of slots constitute 20% to 40% of the inlet face of the media element, and the second plurality of slots constitute 60% to 80% of the inlet face of the media element.

27. The air filtration media element according to any one of claims 18-19, wherein, The first plurality of slots constitute 40% to 60% of the inlet face of the media element, and the second plurality of slots constitute 60% to 40% of the inlet face of the media element.

28. The air filtration media element according to any one of claims 18 - 19, further comprising a third plurality of slots, the third plurality of slots being arranged in a parallel flow with the first plurality of slots and the second plurality of slots; Among them, The first plurality of slots, the second plurality of slots, and the third plurality of slots exhibit differences in slot shape, slot size, or slot cross - sectional area.

29. The air filtration media element according to claim 28, wherein, Each of the first plurality of slots, the second plurality of slots, and the third plurality of slots is disposed in separate pluralities of layers.

30. The air filtration media element according to any one of claims 18-19, wherein The multi-layered media element is arranged in a wound configuration or a stacked configuration.

31. The air filtration media element according to any one of claims 18-19, wherein, The differences in slot shape, slot size, or slot cross-sectional area are regular and repetitive.

32. An air filtration media element for removing particulates from an air stream, the air filtration media element comprising: a) a first plurality of slots; and b) a second plurality of slots disposed in a parallel flow configuration with the first plurality of slots; The second plurality of slots exhibits a difference from the first plurality of slots in slot shape, slot size, or slot cross-sectional area; wherein the first plurality of slots and the second plurality of slots have a common upstream face and a common downstream face; wherein the first plurality of slots is disposed in a first multi-layer slotted medium, and the second plurality of slots is disposed in a second multi-layer slotted medium; wherein when simultaneously loading dust under parallel flow conditions and when the pressure drop across the air filtration media element reaches at least 10 inches of water column, the first plurality of slots and the second plurality of slots perform as follows: a) The time-averaged velocity of the first plurality of slots is less than the time-averaged velocity of the entire filter element and the time-averaged velocity of the second plurality of slots is greater than the time-averaged velocity of the filter element b) The load change ΔL1 of the first plurality of slots is equal to the load L of the first plurality of slots measured at the first plurality of slots time-averaged velocity V 1 avg minus the load L of the first plurality of slots measured at the component time-averaged velocity V 1,(V1 avg) : 元件avg The load L of the first plurality of slots measured at the first plurality of slots time-averaged velocity V 1,(V元件avg) : ΔL1 = L 1,(V1 avg) -L 1,(V元件avg) ΔL1>0 c) The load change ΔL2 of the second plurality of slots is equal to the load L of the second plurality of slots measured at the second plurality of slots time-averaged velocity V 2 avg minus the load L of the second plurality of slots measured at the element time-averaged velocity V 2,(V2 avg) : 元件avg 2,(V元件avg) ​​ ΔL2 = L 2,(V2 avg) -L 2,(V元件avg) ΔL2<0 d) The sum of ΔL1 and ΔL2 is greater than 0: ΔL1 + ΔL2>0.

33. The air filtration media element according to claim 32, wherein, The first plurality of slots constitutes 10% to 90% of the volume of the media element, and the second plurality of slots constitutes 90% to 10% of the volume of the media element.

34. The air filtration media element according to any one of claims 32 - 33, wherein, The first plurality of slots constitutes 20% to 40% of the volume of the media element, and the second plurality of slots constitutes 60% to 80% of the volume of the media element.

35. The air filtration media element according to any one of claims 32 - 33, wherein, The first plurality of slots constitutes 40% to 60% of the volume of the media element, and the second plurality of slots constitutes 60% to 40% of the volume of the media element.

36. The air filtration media element according to any one of claims 32-33, wherein, The first plurality of slots constitutes 10% to 90% of the media surface area of the media element, and the second plurality of slots constitutes 90% to 10% of the media surface area of the media element.

37. The air filtration media element according to any one of claims 32-33, wherein, The first plurality of slots constitutes 20% to 40% of the media surface area of the media element, and the second plurality of slots constitutes 60% to 80% of the media surface area of the media element.

38. The air filtration media element according to any one of claims 32-33, wherein, The first plurality of slots constitutes 40% to 60% of the media surface area of the media element, and the second plurality of slots constitutes 60% to 40% of the media surface area of the media element.

39. The air filtration media element according to any one of claims 32-33, wherein, The first plurality of slots constitutes 10% to 90% of the inlet face of the media element, and the second plurality of slots constitutes 90% to 10% of the inlet face of the media element.

40. The air filtration media element according to any one of claims 32-33, wherein, The first plurality of slots constitutes 20% to 40% of the inlet face of the media element, and the second plurality of slots constitutes 60% to 80% of the inlet face of the media element.

41. The air filtration media element according to any one of claims 32-33, wherein, The first plurality of slots constitutes 40% to 60% of the inlet face of the media element, and the second plurality of slots constitutes 60% to 40% of the inlet face of the media element.

42. The air filtration media element according to any one of claims 32 - 33, further comprising a third plurality of slots arranged in parallel flow with the first plurality of slots and the second plurality of slots; Among them, The first plurality of slots, the second plurality of slots, and the third plurality of slots exhibit differences in slot shape, slot size, or slot cross-sectional area.

43. The air filtration media element according to claim 42, wherein, Each of the first plurality of slots, the second plurality of slots, and the third plurality of slots is disposed in separate pluralities of layers.

44. The air filtration media element according to any one of claims 32-33, wherein, The multi-layered media element is arranged in a wound configuration or a stacked configuration.

45. The air filtration media element according to any one of claims 32 - 33, wherein, The differences in slot shape, slot size, or slot cross-sectional area are regular and repetitive.

46. An air filtration media element for removing particulates from an air stream, the air filtration media element comprising: a) a first plurality of slots; and b) a second plurality of slots, the second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of slots exhibit a difference from the first plurality of slots in slot shape, slot size, or slot cross-sectional area; wherein the first plurality of slots and the second plurality of slots have a common upstream face and a common downstream face; and wherein the first plurality of slots and the second plurality of slots perform as follows: i) the pressure drop ΔP increases as the flow rate Q increases; ii) Before the load, when the first plurality of slots and the second plurality of slots are independently tested at the same speed, the first plurality of slots have an initial pressure drop ΔP that is lower than the initial pressure drop ΔP across the second plurality of slots 2,0 with a lower initial pressure drop ΔP 1,0 ; ΔP 1,0 <ΔP 2,0 iii) When testing is carried out in parallel, the velocity V of the first plurality of slots before the load 1,0 is greater than the average velocity V of the air filtration medium element before the load (元件平均),0 , and the velocity V of the second plurality of slots before the load 2,0 is less than the average velocity V of the air filtration medium element before the load (元件平均),0 ; V 1,0 >V (元件平均),0 V 2,0 <V (元件平均),0 iv) When the tests are carried out in parallel, the pressure drop difference Δ(ΔP1) is equal to the pressure drop ΔP of the first plurality of slots before the load measured at the first plurality of slot velocities V 1,0 minus the pressure drop ΔP of the first plurality of slots before the load measured at the average velocity V of the air filtration medium element 1,0,(V1,0) : 元件avg,0 1,0,(V元件avg,0) ​​ Δ(ΔP1) = ΔP 1,0,(V1,0) -ΔP 1,0,(V元件avg,0) v) When the tests are conducted in parallel, the pressure drop difference Δ(ΔP2) of the second plurality of slots is equal to the pressure drop ΔP of the second plurality of slots before the load measured at the second plurality of slot velocity V 2,0 minus the pressure drop ΔP of the second plurality of slots before the load measured at the air filtration media element average velocity V 2,0,(V2,0) : 元件平均,0 2,0,(V元件平均,0) ​​ Δ(ΔP2) = ΔP 2,0,(V2,0) -ΔP 2,0,(V元件平均,0) vi) the sum of Δ(ΔP1) and Δ(ΔP2) is less than 0: Δ(ΔP1) + Δ(ΔP2) < 0.

47. The air filtration media element according to claim 46, wherein, The first plurality of slots constitute 10% to 90% of the volume of the media element, and the second plurality of slots constitute 90% to 10% of the volume of the media element.

48. The air filtration media element according to any one of claims 46-47, wherein, The first plurality of slots constitute 20% to 40% of the volume of the media element, and the second plurality of slots constitute 60% to 80% of the volume of the media element.

49. The air filtration media element according to any one of claims 46 - 47, wherein, The first plurality of slots constitute 40% to 60% of the volume of the media element, and the second plurality of slots constitute 60% to 40% of the volume of the media element.

50. The air filtration media element according to any one of claims 46 - 47, wherein, The first plurality of slots constitute 10% to 90% of the media surface area of the media element, and the second plurality of slots constitute 90% to 10% of the media surface area of the media element.

51. The air filtration media element according to any one of claims 46 - 47, wherein, The first plurality of slots constitute 20% to 40% of the media surface area of the media element, and the second plurality of slots constitute 60% to 80% of the media surface area of the media element.

52. The air filtration media element according to any one of claims 46 - 47, wherein, The first plurality of slots constitute 40% to 60% of the media surface area of the media element, and the second plurality of slots constitute 60% to 40% of the media surface area of the media element.

53. The air filtration media element according to any one of claims 46 - 47, wherein, The first plurality of slots constitute 10% to 90% of the inlet face of the media element, and the second plurality of slots constitute 90% to 10% of the inlet face of the media element.

54. The air filtration media element according to any one of claims 46 - 47, wherein, The first plurality of slots constitute 20% to 40% of the inlet face of the media element, and the second plurality of slots constitute 60% to 80% of the inlet face of the media element.

55. The air filtration media element according to any one of claims 46-47, wherein, The first plurality of slots constitute 40% to 60% of the inlet face of the media element, and the second plurality of slots constitute 60% to 40% of the inlet face of the media element.

56. The air filtration media element according to any one of claims 46 - 47, further comprising a third plurality of slots arranged in parallel flow with the first plurality of slots and the second plurality of slots; Among them, the first plurality of slots, the second plurality of slots, and the third plurality of slots exhibit a difference in slot shape, slot size, or slot cross-sectional area.

57. The air filtration media element according to claim 56, wherein, Each of the first plurality of slots, the second plurality of slots, and the third plurality of slots is disposed in a separate plurality of layers.

58. The air filtration media element according to any one of claims 46 - 47, wherein, The multi-layer media element is arranged in a wound configuration or a stacked configuration.

59. The air filtration media element according to any one of claims 46 - 47, wherein, The differences in slot shape, slot size, or slot cross-sectional area are regular and repetitive.

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