Filter module, use of gasket in filter, and method for producing gasket for filter module

Abstract

In some aspects, a filter module is provided. The filter module includes: a filter media; a frame surrounding the filter media so as to define a fluid flow path extending between an upstream side and a downstream side of the filter module; and a gasket disposed between the filter media and the frame to provide a sealing tight engagement, where the gasket includes a monolithic sheet folded in an accordion pattern to form a plurality of pleats having a zigzag fold.

Description

Technical Field

[0001] This invention relates to filter modules, the use of gaskets in filters, and methods for manufacturing gaskets for filter modules. Background Technology

[0002] HEPA (High-Efficiency Particulate Air) filters, also known as high-efficiency particulate absorbers or high-efficiency particulate traps, are the efficiency standard for air filters. Common standards require HEPA air filters to remove at least 99.95% of particles with a diameter equal to the maximum penetration particle size (MPPS) from the air passing through. For particles smaller than and larger than MPPS, the filtration efficiency increases.

[0003] Dry heat sterilization and depyrogenation are considered among the most critical process steps in pharmaceutical manufacturing, helping to ensure the sterility of drugs (terminal sterilization) and sterile formulations. Inside these sterilization and depyrogenation tunnels, HEPA filters play an indispensable role in protecting containers (such as vials or pre-filled syringes) from contamination that can pose serious health risks to patients. Operating conditions are challenging, as installed HEPA filters must withstand frequent temperature cycling between ambient temperatures and up to 350°C. Traditional high-temperature HEPA filters use inorganic adhesives or elastic fiberglass gaskets as sealants, which significantly increases the risk of dust falling and filter leakage during use.

[0004] More efficient and / or more effective filters are needed. Summary of the Invention

[0005] According to a first aspect of this disclosure, a filter module is provided, comprising: Filter media; A frame that surrounds the filter medium to define a fluid flow path extending between the upstream and downstream sides of the filter module; and A gasket, which is arranged between the filter media and the frame to provide a tight seal, wherein the gasket comprises a single sheet folded in an accordion pattern to form multiple pleats with serrated folds.

[0006] According to a second aspect of this disclosure, a method of manufacturing a gasket for a filter module is provided, wherein the filter module includes a filter medium; and a frame surrounding the filter medium to define a fluid flow path extending between an upstream side and a downstream side of the filter module, and the gasket is arranged between the filter medium and the frame to provide a tight, sealing engagement, the method comprising: A single sheet is folded in an accordion pattern to form a gasket with multiple folds having serrated folds.

[0007] According to a third aspect of this disclosure, there is provided the use of a gasket in a filter module, wherein the filter module includes a filter medium; and a frame that surrounds the filter medium to define a fluid flow path extending between an upstream side and a downstream side of the filter module, the use including: A gasket is arranged between the filter media and the frame to provide a tight seal, wherein the gasket comprises a single sheet folded in an accordion pattern to form multiple pleats with serrated folds. Attached Figure Description

[0008] Throughout the accompanying drawings, it should be noted that the same reference numerals are used to depict the same or similar elements, features, and structures. The drawings are not necessarily drawn to scale, but generally focus on illustrating aspects of this disclosure. In the following description, some aspects of this disclosure are described with reference to the following drawings, wherein: Figure 1 A block diagram depicting example gaskets according to various embodiments of the present disclosure; Figure 2 A block diagram depicting an example method for manufacturing a gasket for a filter module according to various embodiments of the present disclosure; Figure 3A A block diagram depicting an example filter module according to various embodiments of the present disclosure; Figure 3B and Figure 3C Describing as Figure 3A The example filter module shown is an exploded block diagram; and Figure 4 A block diagram depicting an example use of a gasket in a filter module according to various embodiments of the present disclosure. Detailed Implementation

[0009] The following detailed description refers to the accompanying drawings, which illustrate by way of example the specific details and aspects in which the present disclosure may be practiced. One or more aspects are described in sufficient detail to enable those skilled in the art to practice the present disclosure. Other aspects may be utilized, and structural, logical, and / or electrical changes may be made without departing from the scope of the present disclosure. The aspects of the present disclosure are not necessarily mutually exclusive, as some aspects may be combined with one or more other aspects to form new aspects or embodiments. The aspects are described in connection with methods, and the aspects are described in connection with devices. However, it is understood that aspects described in connection with methods can be similarly applied to devices, and vice versa.

[0010] It should be understood that, unless the context clearly indicates otherwise, the singular terms “a,” “one,” and “the” include the plural reference. Similarly, unless the context clearly indicates otherwise, the word “or” is intended to include “and.”

[0011] Furthermore, it should be understood that the terms “comprise” (and any form of inclusion, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”), and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. Therefore, a method or apparatus that “comprises,” “have,” “includes,” or “contains” one or more steps or elements possesses, but is not limited to, possessing only those steps or elements. Similarly, a method step or apparatus element that “comprises,” “have,” “includes,” or “contains” one or more features possesses, but is not limited to, possessing only those features. Moreover, an apparatus or structure configured in a certain way is configured at least in this manner, but may also be configured in ways not listed.

[0012] As used herein throughout the specification and claims, approximate language can be applied to modify any quantitative expression that allows for variation without altering its underlying function. Therefore, values ​​modified by one or more terms (such as “about”, “substantially”) are not limited to specified exact values, but are within operationally acceptable tolerances for the intended application of the embodiment. In some cases, approximate language may correspond to the precision of the instrument used to measure the value.

[0013] The terms “at least one” and “one or more” can be understood to include a numerical quantity greater than or equal to one (e.g., one, two, three, four, etc.). The term “multiple” can be understood to include a numerical quantity greater than or equal to two (e.g., two, three, four, five, etc.). The phrase “at least one of…” relating to a group of elements can be used herein to mean at least one element from a group of these elements. For example, the phrase “at least one of…” relating to a group of elements can be used herein to mean a choice of: one element listed, multiple elements of one type of listed element, multiple individually listed elements, or multiple multiple listed elements. As used herein, a phrase of the form “at least one of A or B” can include A or B or both A and B. Correspondingly, a phrase of the form “at least one of A, B, or C”, or including additionally listed items, can include any and all combinations of one or more of the relevant listed items.

[0014] The terms “plural” and “multiple” in the specification and claims explicitly refer to a quantity greater than one. Therefore, any phrase explicitly referring to a certain number of objects (e.g., “multiple (objects)”, “multiple (objects)”) explicitly refers to more than one of the stated objects. If applicable, the terms “group”, “set”, “collection”, “series”, “sequence”, “grouping”, etc., in the specification and claims refer to a quantity equal to or greater than one, i.e., one or more.

[0015] Unless otherwise stated, the terms “first,” “second,” and “third” used in detail herein are used to distinguish one element from another similar element and may not necessarily indicate order or relative importance. For example, “first transaction data” and “second transaction data” can be used to distinguish two transactions based on the exchange of two different foreign currencies.

[0016] The following examples relate to various aspects of this disclosure.

[0017] Example 1 is a filter module comprising: a filter medium; a frame surrounding the filter medium to define a fluid flow path extending between an upstream side and a downstream side of the filter module; and a gasket disposed between the filter medium and the frame to provide a tight, sealed engagement, wherein the gasket comprises a monolithic sheet folded in an accordion pattern to form a plurality of pleats with serrated folds.

[0018] In Example 2, the subject matter of Example 1 may optionally include: a first sealant disposed between the filter media and the gasket and / or between the gasket and the frame, wherein the sealant comprises a one-component or two-component silicone sealant.

[0019] In Example 3, the subject matter of Example 1 or Example 2 may optionally include: an end portion of a monolithic sheet folded to surround a plurality of folds having serrated folds, wherein the end portion of the monolithic sheet is at least partially sealed to the plurality of folds of the monolithic sheet by a second sealant.

[0020] In Example 4, the subject of Example 3 may optionally include: the end portion of the monolithic sheet is sealed to the last fold of a plurality of folds of the monolithic sheet by a second sealant.

[0021] In Example 5, the subject of Example 3 when subordinate to Example 2 may optionally include: the first sealant includes the same sealant as the second sealant.

[0022] In Example 6, the subject matter of Example 3 or Example 5, when subordinate to Example 2, may optionally include: the first sealant and / or the second sealant comprising an organic heat-resistant adhesive.

[0023] In Example 7, the subject matter of any one of Examples 1 to 6 may optionally include: a gasket with a thickness in the range of 5 to 10 mm spanning multiple folds having serrated folds.

[0024] In Example 8, the subject matter of Example 7 may optionally include: the thickness of the gasket disposed between the filter media and the frame is compressible to at least about half of the original thickness that the gasket has in its uncompressed state.

[0025] In Example 9, the subject matter of any of Examples 1 through 8 may optionally include: monolithic sheets comprising glass or mineral fibers made of borosilicate glass fibers.

[0026] In Example 10, the subject matter of any of Examples 1 to 9 may optionally include: multiple pleats of a single sheet having uniform dimensions.

[0027] In Example 11, the subject matter of any one of Examples 1 to 10 may optionally include: the filter medium comprising a continuous sheet folded in an accordion pattern to form a plurality of pleats, wherein corrugated spacers are disposed between the successive pleats of the continuous sheet.

[0028] In Example 12, the subject matter of any one of Examples 1 to 11 may optionally include: a frame comprising first, second, third, and fourth sections surrounding the filter medium on its four sides, wherein each of the first, second, third, and fourth sections includes a reinforcing connector connecting and abutting adjacent sections, the reinforcing connector being L-shaped, and wherein each of the first, second, third, and fourth sections includes at least one reinforcing member disposed on its outer surface and arranged in a direction parallel to the fluid flow path extending between the upstream and downstream sides of the filter module.

[0029] Example 13 is a method of manufacturing a gasket for a filter module, wherein the filter module includes a filter medium; and a frame that surrounds the filter medium to define a fluid flow path extending between an upstream side and a downstream side of the filter module, and the gasket is arranged between the filter medium and the frame to provide a tight, sealed engagement, the method comprising: folding a monolithic sheet in an accordion pattern to form a gasket including a plurality of pleats having serrated folds.

[0030] In Example 14, the subject matter of Example 13 may optionally include: folding the end portion of a monolithic sheet around a plurality of folds having serrated folds, and at least partially sealing the end portion of the monolithic sheet to the plurality of folds of the monolithic sheet with a sealant.

[0031] Example 15 is an example of the use of a gasket in a filter module, wherein the filter module includes a filter medium; and a frame that surrounds the filter medium to define a fluid flow path extending between an upstream side and a downstream side of the filter module. The use includes arranging the gasket between the filter medium and the frame to provide a tight, sealed engagement, wherein the gasket comprises a monolithic sheet folded in an accordion pattern to form multiple pleats with serrated folds.

[0032] Figure 1 An enlarged view 101 shows a gasket 100 and a portion thereof according to various embodiments of the present disclosure.

[0033] In the context of various embodiments, the term "gasket" refers to an element, component, or structure configured to seal a gap, joint, or space between two other elements, parts, or structures. Gaskets may be made of shaped sheets or rings of material, including but not limited to rubber or other materials. Specifically, the term "gasket" refers to a flexible or resilient component arranged (e.g., biased) between the filter media and frame of a filter module to provide a tight-fitting seal, wherein the filter module includes the filter media; and the frame surrounds the filter media to define a fluid flow path extending between an upstream and downstream side of the filter module. The fluid may be air. In some embodiments, the fluid may be air in a sterilization tunnel and / or a depyrogenation tunnel.

[0034] According to various non-limiting embodiments, the gasket 100 may include a single-piece (e.g., integral, monolithic) sheet 110. The single-piece sheet 110 may be folded in an accordion-like manner to form a plurality of pleats 111 having serrated folds 111'. According to various non-limiting embodiments, the end portions 113 of the single-piece sheet 110 may be folded to surround (e.g., wrap, cover) the plurality of pleats 111 having serrated folds 111'. The plurality of pleats 111 may be held in place by the end portions 113. Thus, the gasket 100 may have a structured and / or smooth appearance. Figure 2 As shown, the end portion 113 of the monolithic sheet 100 may include a segment 113a sized to accommodate the thickness across a plurality of pleats 111, particularly the thickness between the first pleat 111a and the last pleat 111z. The end portion 113 of the monolithic sheet 110 may include a segment 113b sized to accommodate the length of each of the plurality of pleats 111, the length of the pleat in the longitudinal direction of the monolithic sheet 100. The end portion 113 of the monolithic sheet 110 may include two segments 113a and two segments 113b, such that the end portion 113 can surround the plurality of pleats 111.

[0035] According to various non-limiting embodiments, the monolithic sheet 110 may comprise, for example, glass or mineral fibers made of borosilicate glass fibers. The gasket 100 can be applied in high-temperature, high-efficiency filters (e.g., filter modules) capable of withstanding 300-400°C for extended periods. The gasket 100 can be manufactured by folding using a standard pleating machine, and therefore its dimensions can be controllable; for example, the dimensions of each pleat can be uniform. In other words, the multiple pleats of the monolithic sheet 110 can have uniform dimensions. This gasket 100 can advantageously be manufactured with high production efficiency to produce gaskets with controllable dimensions, thereby improving efficiency (e.g., reinforcing the practical application in which the gasket 100 can be used). Because the gasket 100 comprises multiple pleats 111 folded in an accordion-like pattern, the gasket 100 can be biased between the filter media and the frame of the filter module, thereby enhancing sealing and / or improving efficiency (reducing contamination of downstream filtered fluid due to leakage).

[0036] According to various non-limiting embodiments, the end portion 113 of the monolithic sheet 110 can be at least partially sealed to a plurality of pleats 111 of the monolithic sheet 110 by a sealant 120. In some embodiments, the end portion 113 of the monolithic sheet 110 can be sealed to the last pleat 111z of the plurality of pleats 111 of the monolithic sheet 110 by the sealant 120, such as Figure 1 and Figure 2 As shown in illustration 101. In some embodiments, the segment 113b of the end portion 113 may be sealed to the last pleat 111z of the plurality of pleats 111 by a sealant 120. In some embodiments, the end portion 113 or segment 113b of the monolithic sheet 110 may be sealed to the outside of the last pleat 111z of the plurality of pleats 111 of the monolithic sheet 110 by a sealant 120, the outside of the last pleat 111z being one of the two faces of the last pleat 111z facing the end portion 113 or segment 113b of the monolithic sheet 110, as shown in the illustration 101. Figure 1 and Figure 2As shown in illustration 101. In some embodiments, the end portion 113 may be sealed to a first fold 111a among a plurality of folds 111 by a sealant 120. In some embodiments, a segment 113b of the end portion 113 may be sealed to the first fold 111a among a plurality of folds 111 by a sealant 120. In some embodiments, the end portion 113 or segment 113b may be sealed to the outside of the first fold 111a by a sealant 120, the outside of the first fold 111a being one of the two faces of the first fold 111a facing the end portion 113 or segment 113b of the monolithic sheet 110. In some embodiments, the end portion 113 may be sealed to a serrated fold 111' by a sealant 120. In some embodiments, a segment 113a of the end portion 113 may be sealed to the serrated fold 111' by a sealant 120. In some embodiments, one or two end segments 113a and / or one or two end segments 113b may be at least partially sealed to a plurality of pleats 111 and / or serrated folds 111' by a sealant 120, thereby surrounding a plurality of pleats 111 having serrated folds 111'. In some embodiments, the last pleat 111z may be further sealed to the penultimate pleat 111y of a plurality of pleats 111 in the monolithic sheet 110 by a sealant 120 (not shown).

[0037] According to various non-limiting embodiments, sealant 120 may comprise an organic, flexible, temperature-resistant (e.g., heat-resistant) adhesive. Sealant 120 may have high bond strength and good sealing performance. Therefore, there are no limitations on temperature rise conditions for the filter module including gasket 100. Thus, the filter module may be able to withstand frequent temperature cycling between ambient temperature and approximately 500°C, 450°C, 400°C, or 350°C. Sealant 120 may be a sealant initially in liquid form and capable of hardening to form an impermeable solid. When using commercially available double-sided adhesives or nonwoven sealing gaskets, the application of sealant 120 advantageously eliminates the risk of dust particles falling off, thereby providing higher production efficiency than other products. Applying sealant 120 to the end portion 113 to at least partially surround and / or seal multiple folds further advantageously allows gasket 100 to have controlled dimensions and a structured and / or smooth appearance. Furthermore, the application of sealant 120 advantageously avoids the use of double-sided adhesive bonding or nonwoven thermal bonding during temperature cycling, and thus avoids the shedding of dust particles caused by the high-temperature carbonization of such inorganic adhesives or nonwoven elastic sealants.

[0038] According to various non-limiting embodiments, sealant 120 may include a one-component or AB two-component liquid sealant (e.g., silicone). The one-component liquid adhesive, and its main components, may be silicone resin, hydrogen-containing silicone oil, and a catalyst, etc. The organic heat-resistant adhesive may be a self-reactive adhesive containing a catalyst, which can cure slowly at low temperatures or rapidly by heating, and does not require the participation of airborne components in the reaction, nor release substances into the air. For AB two-component silicone, adhesive A may be the main adhesive, and its main components may be silicone resin, hydrogen-containing silicone oil, etc., and adhesive B may be a curing agent, also known as a catalyst. Adhesive A and adhesive B may be mixed in a certain proportion and stirred evenly. The mixture may cure slowly at room temperature or rapidly by heating. The mixture may not require the participation of airborne components in the reaction and may not release substances into the air.

[0039] According to various non-limiting embodiments, the monolithic sheet 110 may comprise glass or mineral fibers. The glass or mineral fibers may be borosilicate glass fibers. The gasket 100, comprising the folded monolithic sheet 110, advantageously optimizes the integrity of the seal between the filter media and the frame of the filter module, and thus maintains the structural rigidity and filtration efficiency of the filter when exposed to high temperatures for a considerable period, and particularly when subjected to repeated cycles between low temperatures (e.g., about 25°C) and high temperatures (e.g., in the range of 200-500°C).

[0040] According to various non-limiting embodiments, the thickness of the gasket 100 across a plurality of pleats 111 having serrated folds can be provided (in... Figure 1 The thickness "T" is used to accommodate any gap between the filter media and the frame. In some embodiments, the thickness "T" may be greater than any gap between the filter media and the frame. In one example, the thickness is in the range of 5 to 10 mm. When the gasket 100 is arranged between the filter media and the frame, the gasket 100 can be compressed within the gap to provide a tight seal. In some embodiments, the thickness of the gasket 100 may be compressed to about 90%, about 80%, about 70%, or about 60% of its original thickness in the uncompressed state. In one example, the thickness of the gasket 100 may be compressed to about 3 to 7 mm. Because the gasket 100 is compressible, it may be able to expand when the frame expands, thereby providing a flexible seal between the filter media and the frame.

[0041] Figure 2 A block diagram depicting an example method 200 for manufacturing a gasket for a filter module according to various embodiments of the present disclosure. Figure 2 The gasket shown can be used with, for example Figure 1The gaskets 100 shown are identical or similar, and therefore, common features are labeled with the same reference numerals. Various modifications can be made to the gasket 100 as described herein. Figure 2 The gasket shown is modified in a similar manner to that described for reference gasket 100, and vice versa.

[0042] In step 210, the monolithic sheet 110 is first folded to include a first fold 111a having a first serrated fold 111a'.

[0043] At step 220, the monolithic sheet 110 is further folded to include a second fold 111b having a second serrated fold 111b'. The second fold 111b may have the same dimensions as the first fold 111a; for example, the second fold 111b may have the same length as the first fold 111a in the longitudinal direction of the monolithic sheet 110. In other words, the second fold 111b may overlap with the first fold 111a, specifically, completely or entirely overlap with the first fold 111a.

[0044] At step 230, the monolithic sheet 110 continues to be folded to further include multiple pleats until the last pleat 111z has a last serrated fold 111z' and an end portion 113. Thus, the monolithic sheet 110 is folded in an accordion pattern to form multiple pleats (111a, ..., 111z) with serrated folds (111a', ..., 111z'). The serrated folds including 111a', 11b', ..., 111z' may include semicircles, V-shapes, conical shapes, or other suitable shapes. In some embodiments, the odd-numbered serrated folds may be a first identical shape and the even-numbered serrated folds may be a second identical shape. The first identical shape may be the same as the second identical shape. The end portion 113 may have a length equal to or greater than the periphery of the plurality of folds (111a, ..., 111z) having serrated folds (111a', ..., 111z') (i.e., twice the length of each plurality of folds (111a, ..., 111z) having the same length plus twice the thickness of the plurality of folds (111a, ..., 111z) having serrated folds (111a', ..., 111z'), such that the length of the end portion 113 is sufficient to surround the plurality of folds (111a, ..., 111z) having serrated folds (111a', ..., 111z'). The end portion 113 may include a segment 113a adjacent to the last fold 111z. Segment 113a may have a length (i.e., length in the longitudinal direction of the monolithic sheet 100) to accommodate the thickness across multiple pleats 111, specifically the thickness between the first pleat 111a and the last pleat 111z. A serrated fold may connect segment 113a and the last pleat 111z. End portion 113 may include a segment 113b adjacent to segment 113a. Segment 113b may have a length (i.e., length in the longitudinal direction of the monolithic sheet 100) to accommodate the length of multiple pleats 111. A serrated fold may connect segment 113b and segment 113a. End portion 113 may include another segment 113a and another segment 113b, such that the length of end portion 113 is sufficient to surround multiple pleats (111a, ..., 111z) having serrated folds (111a', ..., 111z').

[0045] According to various non-limiting embodiments, the number of pleats can be determined according to actual needs. Therefore, the thickness of the gasket can be controllably determined by the product of the number of pleats and the thickness of the single-piece sheet. It should be understood that the single-piece sheet 110 can include any number of pleats, including even and odd numbers as needed.

[0046] At steps 240 and 250, the end portion 113 of the monolithic sheet 110 is folded to surround a plurality of pleats (111a, ..., 111z) having serrated folds (111a', ..., 111z'). In some embodiments, the gap between the end portion 113 and the serrated folds can be minimal when the odd number of serrated folds can be a first identical shape and the even number of serrated folds can be a second identical shape. In other words, the gasket can be cuboid in shape, having two sets of parallel planes, with one set of parallel planes perpendicular to the other set of parallel planes.

[0047] At step 260, sealant 120 is applied to the end-facing portion 113 of the last fold 111z. In some embodiments, sealant 120 may be applied to the end-facing portion 113 of the first fold 111a. In some embodiments, sealant 120 may be applied to the serrated fold 111', or particularly to the end-facing portion 113 of the serrated fold 111'.

[0048] At step 270, the end portion 113 (e.g., a first segment 113b of the end portion 113 that is similar in size to or the same as the last fold 111z) is sealed to the last fold 111z by sealant 120. Alternatively or additionally, sealant 120 may be applied to even and / or odd serrated folds to seal the end portion 113 (e.g., a segment 113a of the end portion that is similar in size to or the same as the serrated fold) to the serrated fold. Alternatively or additionally, sealant 120 may be applied to the side of the first fold 111a facing the end portion 113 to seal the end portion 113 (e.g., a fourth segment 113b of the end portion 113 that is similar in size to or the same as the first fold 111a) to the first fold 111a. This method 200 provides the gasket with a structured and / or smooth aesthetic appearance and versatility for many practical applications.

[0049] Figure 3A Block diagrams depicting filter module 300 according to various embodiments of the present disclosure; and Figure 3B and 3C Describing as Figure 3A The exploded block diagram of the filter module 300 is shown.

[0050] According to various non-limiting embodiments, the filter module 300 may include a filter medium 310; a frame 340 that surrounds the filter medium 310 to define a fluid flow path extending between an upstream and downstream side of the filter module 300; and gaskets 320 (including 321, 322, 323, 324) disposed between the filter medium 310 and the frame 340 to provide a tight, sealing engagement. Figure 3A ,3B The gaskets 320 (including 321, 322, 323, and 324) shown in 3C can be used with, for example... Figure 1 The gasket 100 and / or shown Figure 2 The gasket 200 shown is the same as or similar to the gaskets 100 and 200 described herein. Various modifications can be made to gaskets 100 and 200 as described herein. Figure 3A , 3B As shown in 3C, gaskets 320 (including 321, 322, 323, 324) can be modified in a manner similar to those described for reference gaskets 100, 200, and vice versa.

[0051] In the context of various embodiments, the term "sealed tight engagement" refers to a tight seal formed between adjacent components, such as between gaskets 320 (including 321, 322, 323, 324) and filter media 310, and between gaskets 320 (including 321, 322, 323, 324) and frame 340, such that fluid flowing through filter media 310 is not allowed to enter or pass through the seal; that is, the seal is impermeable or impermeable to fluid.

[0052] According to various non-limiting embodiments, and with reference to Figure 3A , 3B In conjunction with 3C, gaskets 320 (321, 322, 323, 324) may comprise monolithic sheets folded in an accordion pattern to form multiple pleats with serrated folds, and the end portions of the monolithic sheets are folded to surround the multiple pleats with serrated folds. Filter modules 300 including gaskets 320 (including 321, 322, 323, 324) offer advantages such as no particle shedding, no sealant cracking, high bond strength, simple manufacturing process, and unrestricted temperature rise. This filter module 300 can advantageously withstand temperatures of 300-400°C for extended periods and meets the requirements of European standard EN 1822-2009 H13 or higher for HEPA filters, or higher than ISO 35H ​​level in ISO 29463.

[0053] According to various non-limiting embodiments, the filter medium 310 may comprise an integral (e.g., one-piece or continuous) sheet folded in an accordion pattern to form multiple pleats, wherein corrugated spacers (not shown) are disposed between the continuous pleats of the continuous sheet. The corrugated spacers may be made of stainless steel or aluminum, folded into a corrugated shape and sandwiched between the filter medium in the accordion-folded structure, thereby advantageously ensuring that the pleats of the filter medium will not collapse due to prolonged use at high temperatures and affect ventilation channels, for example, by reducing the surface area of ​​the filter medium.

[0054] According to various non-limiting embodiments, frame 340 may be a box-type metal (e.g., stainless steel, including but not limited to SUS201 / 304 / 316 / 316L) frame. Frame 340 may include first, second, third, and fourth sections (341, 342, 343, 344) surrounding filter media 310 on its four sides. Each of the first, second, third, and fourth sections (341, 342, 343, 344) may include a reinforcing connector (e.g., [missing information]) connecting adjacent frame sections and abutting adjacent sections. Figure 3C (As shown in 345a, 345b, 345c, 345d). Figure 3C As shown, the reinforcing connector is L-shaped. The reinforcing connector can be made of the same material as frame 340 to connect sections of frame 340 (341, 342, 343, 344) to avoid expansion and displacement of different coefficients at high temperatures, and to ensure that the sealant and filter elements are not torn under high temperature conditions.

[0055] According to various non-limiting embodiments, each of the first, second, third, and fourth sections (341, 342, 343, 344) may include at least one reinforcement disposed on its outer surface and arranged in a direction parallel to the fluid flow path extending between the upstream and downstream sides of the filter module 300. For example, the fourth section 343 may include three reinforcements 343a, 343b, and 343c, such as Figure 3A As shown. The stiffeners can be made of the same material as frame 340 to avoid expansion and displacement at different coefficients at high temperatures.

[0056] According to various non-limiting embodiments, gaskets 320 (321, 322, 323, 324) may be arranged between each of the four sides of the filter medium 310 and each of the four segments of the frame 340 to provide a tight, sealed engagement. A sealant may be disposed between the filter medium 310 and the gaskets 320 (321, 322, 323, 324) and / or between the gaskets 320 (321, 322, 323, 324) and the frame 340. The sealant of the filter module 300 may be consistent with reference to... Figure 1 The sealant 120 is similar to or the same as described above.

[0057] For example, a sealant is disposed between the filter medium 310 and the gaskets 320 (321, 322, 323, 324) and between the gaskets 320 (321, 322, 323, 324) and the frame 340, such as... Figure 3BThe example shows gasket 321 for the placement of sealants 331 and 332. In this example, the sealant is placed between the filter medium 310 and gaskets 320 (321, 322, 323, 324), but not between gaskets 320 (321, 322, 323, 324) and the frame 340, as shown. Figure 3B The image shows gasket 324 with sealant 337. In another example, the sealant is not disposed between the filter media 310 and gaskets 320 (321, 322, 323, 324), but between gaskets 320 (321, 322, 323, 324) and frame 340, as shown. Figure 3B The image shows gasket 323 with sealant 335. In another example, the sealant is not disposed between the filter media 310 and gaskets 320 (321, 322, 323, 324), nor between gaskets 320 (321, 322, 323, 324) and frame 340, as shown. Figure 3B The gasket 322 shown in the text is for a gasket without a sealant. Although Figure 3B Four possible embodiments of the filter module 300 are shown, but it should be understood that a preferred arrangement is one where the same sealant is used between the filter media 310 and the gaskets 320 (321, 322, 323, 324) and between the gaskets 320 (321, 322, 323, 324) and the frame 340. For simplicity, Figure 3C The sealant arrangement in filter module 300 is not shown.

[0058] Figure 4 A block diagram depicting an example use of a gasket 420 in a filter module 400 according to various embodiments of the present disclosure. A front view of the filter module 400 is shown as 400a, and a side view of the filter module 400 is shown as 400b.

[0059] According to various non-limiting embodiments, the filter module 400 may include a filter medium 410; and a frame that surrounds the filter medium 410 to define a fluid flow path extending between an upstream and downstream side of the filter module 400. The use of a gasket 420 in the filter module 400 may include arranging the gasket 420 between the filter medium 410 and the frame to provide a tight, sealable engagement, wherein the gasket 420 may include a monolithic sheet folded in an accordion-like manner to form a plurality of pleats with serrated folds. According to various non-limiting embodiments, end portions of the monolithic sheet are folded to surround the plurality of pleats with serrated folds. Figure 4 The gasket 420 shown can be used with, for example Figure 1 The gasket 100 and / or shown Figure 2 The gasket 200 shown and / or as shown Figures 3A to 3CThe gasket 320 shown is the same as or similar to the gaskets 100, 200, and 320. Gasket 420 can be modified in a similar manner to those described for reference gaskets 100, 200, and 320, and vice versa.

[0060] According to various non-limiting embodiments, the gasket 420 can maintain a sealed engagement between the filter medium 410 and the closed frame around its entire periphery.

[0061] According to various non-limiting embodiments, at least one reinforcing connector 345' is provided to connect adjacent sections of the frame. For example, Figure 4 The diagram shows three reinforcing connectors 345' for connecting two adjacent sections of the frame.

[0062] While this specification contains numerous details, these details should not be construed as limiting the scope of the claims, but rather as descriptions of features specific to particular examples. Certain features described in this specification or illustrated in the accompanying drawings in the context of individual embodiments may also be combined. Conversely, various features described or illustrated in the context of a single embodiment may also be implemented individually or in any suitable sub-combination in multiple embodiments.

Claims

1. A filter module comprising: Filter media; A frame that surrounds the filter medium to define a fluid flow path extending between the upstream and downstream sides of the filter module; as well as A gasket, disposed between the filter media and the frame to provide a tight, sealed fit, wherein the gasket comprises a single sheet folded in an accordion pattern to form multiple pleats with serrated folds.

2. The filter module according to claim 1, further comprising: A first sealant is disposed between the filter medium and the gasket and / or between the gasket and the frame. The sealant mentioned above includes single-component or two-component silicone sealants.

3. The filter module according to claim 1 or claim 2, wherein the end portion of the monolithic sheet is folded to surround the plurality of folds having serrated folds, and wherein the end portion of the monolithic sheet is at least partially sealed to the plurality of folds of the monolithic sheet by a second sealant.

4. The filter module of claim 3, wherein the end portion of the monolithic sheet is sealed to the last of the plurality of folds of the monolithic sheet by the second sealant.

5. The filter module according to claim 3 when dependent on claim 2, wherein the first sealant comprises the same sealant as the second sealant.

6. The filter module according to claim 3 or 5 when dependent on claim 2, wherein the first sealant and / or the second sealant comprises an organic heat-resistant adhesive.

7. The filter module according to any one of claims 1 to 6, wherein the thickness of the gasket spanning the plurality of folds having serrated folds is in the range of 5 to 10 mm.

8. The filter module of claim 7, wherein the thickness of the gasket disposed between the filter medium and the frame is compressible to at least about half of the original thickness of the gasket in its uncompressed state.

9. The filter module according to any one of claims 1 to 8, wherein the monolithic sheet comprises glass or mineral fibers made of borosilicate glass fibers.

10. The filter module according to any one of claims 1 to 9, wherein the plurality of pleats of the monolithic sheet have uniform dimensions.

11. The filter module according to any one of claims 1 to 10, wherein the filter medium comprises a continuous sheet folded in an accordion pattern to form a plurality of pleats, wherein corrugated spacers are disposed between the continuous pleats of the continuous sheet.

12. The filter module according to any one of claims 1 to 11, The frame comprises first, second, third, and fourth sections that surround the filter medium on its four sides. Each of the first, second, third, and fourth segments includes a reinforcing connector that connects and is adjacent to the adjacent segment, the reinforcing connector being L-shaped, and Each of the first, second, third, and fourth sections includes at least one reinforcing member disposed on its outer surface and arranged in a direction parallel to the fluid flow path extending between the upstream and downstream sides of the filter module.

13. A method of manufacturing a gasket for a filter module, wherein the filter module includes a filter medium; and a frame surrounding the filter medium to define a fluid flow path extending between an upstream side and a downstream side of the filter module, and the gasket is disposed between the filter medium and the frame to provide a tight, sealing engagement, the method comprising: A single sheet is folded in an accordion pattern to form a gasket with multiple folds having serrated folds.

14. The method of claim 13, further comprising folding the end portions of the monolithic sheet to surround the plurality of folds having serrated folds, and the end portions of the monolithic sheet being at least partially sealed to the plurality of folds of the monolithic sheet by a sealant.

15. Use of a gasket in a filter module, wherein the filter module includes a filter medium; and a frame that surrounds the filter medium to define a fluid flow path extending between an upstream side and a downstream side of the filter module, the use comprising: The gasket is arranged between the filter medium and the frame to provide a tight, sealed connection, wherein the gasket comprises a single sheet folded in an accordion pattern to form multiple pleats with serrated folds.

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