Variable height, offset, bevel bridged embossing

Abstract

A pleated filter media package includes a filter media sheet folded along pleat folds to provide a plurality of pleats having panels. A plurality of elongate embossments formed in the filter media sheet are laterally separated by unembossed / flat regions. The at least one feature provides any one or more of: lateral bridge strength between the elongate embossments, panel / embossed stiffness, or discontinuous contact points. Such features may include any one or more of the following: a variable height embossing, wherein a saddle is formed into the embossing; offset alignment of the elongate embossments; bridging embossing is formed into the non-embossed / flat area; or angled alignment of the elongate embossments.

Description

Cross-referencing of related patent applications

[0001] This patent application claims the benefit of U.S. Provisional Patent Application No. 63 / 622,958, filed January 19, 2024, and U.S. Provisional Patent Application No. 63 / 540,728, filed September 27, 2023, the entire teachings and disclosures of which are incorporated herein by reference. Technical Field

[0002] This disclosure relates to feature enhancement for use in conjunction with embossing for filter media. Background Technology

[0003] An example of current embossing is shown in U.S. Patent Publication US2022 / 0096985 A1, entitled “FILTER MEDIA PACKS, METHODS OF MAKING AND FILTER MEDIA PRESSES”, by Tate et al., the entire disclosure of which is incorporated herein by reference. Additional embossing patterns are shown in U.S. Patent Publication US2021 / 0229021 A, entitled “PLEATED CHANNEL FLOWFILTER AND / OR ROLL FORM METHOD”, by Copley et al.; however, this design requires sealing the inlet and outlet ends of the filter media sheet. Yet another embossing pattern in a pleated filter element is shown in U.S. Patent Publication US 7,425,227 B1, entitled “PLEATED FILTER ELEMENT WITH OFFSET EMBOSS PATTERN”, granted to Hutchison et al. '227 patent discloses a pleated filter medium having multiple pleats with peaks and valleys, and an array of elongated embossings protruding from its clean side and dirty side; and the elongated embossings are positioned such that the elongated embossings imprinted on adjacent pleats of the filter medium are offset from each other in a direction parallel to the peaks and valleys.

[0004] The current embossing design in filter media tends to obscure the next sheet along the length of the embossing, making the media less effective. Furthermore, the current embossing design is inefficient and prone to loosening in certain types of filter media. Summary of the Invention

[0005] The various embossing improvements described in this article better preserve or open space for the medium to remove contaminants and allow for additional airflow. Additionally, the opening between the embossed tip and the flat sheet allows airflow to diffuse through the embossed channels, improving airflow and medium usage.

[0006] This disclosure relates to improvements to embossing patterns having one or more embossing reinforcement features that can take various forms, which can be used alone or in various combinations with each other.

[0007] In a first embodiment, variable-height embossing in the form of elongated ridges or channels extends through the filter media, providing structure to the media, reducing blinding-off, and preventing slackness of the embossing perpendicular to the embossing direction. In another embodiment, offset / biased embossing adds structure to the pack by shortening the "beam" to prevent the pack from collapsing under high differential pressure. In a third embodiment, embossing support bridges add structure to the unembossed / flat portions between embossings, supporting the pack to prevent collapse under high differential pressure and reducing media blinding. In yet another fourth embodiment, angled / oblique embossing reduces media blinding, can facilitate continuous embossing processes, and can allow for customized pleat heights without significant tooling / processing changes. Additionally, the speculative effect of the turbulent airflow generated by alternating flow paths can produce a scavenging effect within the media pack to distribute contaminants more evenly throughout the media. Furthermore, various additional embodiments involve different combinations of any two or more of these four embodiments of embossing enhancement features.

[0008] The improvements of this invention provide structural solutions for embossing and media packaging. For example, cellulose media tend to loosen or partially revert to their original sheet form. While these improvements are useful for media that are not primarily cellulose, they are particularly useful and beneficial for media that are primarily (if not primarily) cellulose fibers. Various embossing improvements help support the embossing to prevent loosening. These improvements also facilitate a monolithic packaging structure during high flow rates. These geometric improvements can be used alone or in combination with one or more embodiments, and can be achieved without the use of adhesives typically used to address this problem.

[0009] According to one aspect of the invention, a pleated filter media package includes a filter media sheet folded along pleats at an inlet flow surface and pleats at an outlet flow surface to provide a plurality of pleats having a panel extending between the inlet and outlet flow surfaces. A plurality of elongated embossings are formed in the filter media sheet and extend longitudinally between the inlet and outlet flow surfaces. The elongated embossings are laterally spaced and separated by unembossed / flat areas. The filter media package also includes at least one feature. At least one of these features includes any one or more of the following: (a) a saddle formed in the elongated embossing that is raised relative to the unembossed / flat area; or (b) an offset alignment of the elongated embossing, including a first set of elongated embossing on a first panel and a second set of elongated embossing on a second panel, the second set of elongated embossing protruding in a direction common to the first set, wherein the first set of elongated embossing engages the corresponding area of ​​the unembossed / flat area of ​​the second panel at a lateral midpoint defined between corresponding adjacent embossings in the corresponding area of ​​the unembossed / flat area of ​​the second panel; or (c) a bridging embossing formed in the unembossed / flat area, the bridging embossing extending laterally between adjacent members of the elongated embossing; or (d) an angled alignment of the elongated embossing, wherein the elongated embossing extends relative to the fold at an angle and in an intermittent contact position.

[0010] This at least one feature (which may also be considered as embossing reinforcement) can provide any one or more of the following: (a) lateral bridging strength between slender embossings, (b) panel / embossing stiffness, or (c) intermittent contact points.

[0011] As detailed in the following paragraphs, various additional aspects and features may be used individually or in combination with each other with aspects of the invention.

[0012] Additional optional features available in filter media packaging with any embossing enhancement features One feature is that the elongated embossing can extend between 75% and 99% of the panel span between the inlet and outlet flow surfaces, and more preferably between 95% and 99% of the panel span between the inlet and outlet flow surfaces.

[0013] One feature is that the creasing region can extend laterally between opposite edges of the filter media sheet. The creasing region has a width parallel to the opposite edges, spanning between 0.1 cm and 3.0 cm, more preferably between 0.2 cm and 1.0 cm. Furthermore, at least one crisscross is formed in each creasing region to facilitate folding; and elongated embossing resides outside the creasing region and tapers towards the creasing region at the opposite end of the elongated embossing.

[0014] One characteristic is that all the elongated embossings can extend continuously across the entire span between the crease areas at opposite ends of the elongated embossing.

[0015] One feature is that aspects of the invention can be used in deeper filter media packaging, wherein the panel extends a span of 7 to 45 cm, more preferably a span of 10 to 35 cm, between the inlet flow surface and the outlet flow surface.

[0016] In aspects of the present invention, the filter media sheet may include cellulose fibers, synthetic polymer fibers, or glass fibers.

[0017] One feature is that the filter media sheet may include a blend of fibers comprising cellulose fibers and synthetic polymer fibers, wherein the blend of fibers comprises more than 50% cellulose fibers by weight percentage; and more preferably between 70%-90% cellulose fibers and 10%-30% synthetic polymer fibers; and most preferably between 75%-85% cellulose fibers and 15%-25% synthetic polymer fibers.

[0018] One feature is that no adhesive can be applied inside the pleated filter media package between the panels of the filter media sheet.

[0019] One feature is that the elongated embossing may include a maximum depth between 1.0 mm and 4.5 mm, more preferably between 1.0 mm and 2.0 mm, and most preferably between 1.3 mm and 1.6 mm.

[0020] One feature is that, within the inner area of ​​the pleated filter media package, the lateral span of the unembossed / flat area can be at least 200% of the lateral span of each elongated embossing, more preferably between 200% and 600%, and most preferably between 225% and 325%.

[0021] In some embodiments, a feature is that all the elongated embossings can face the same direction within the pleated filter media package, wherein the pleated filter media package has a series of alternating first and second panels. Utilizing this feature, the elongated embossings on the first panel project outwards from a first side of the filter media sheet, and the elongated embossings on the second panel project outwards from a second side of the filter media sheet opposite to the first side.

[0022] One feature is that at least one feature (e.g., an embossing reinforcement feature) can provide bridging strength and intermittent contact points laterally between embossings.

[0023] According to some implementations, one feature is that at least one feature (e.g., embossing enhancement feature) may include at least two features selected from the group consisting of: (a) saddle, (b) offset alignment, and (c) bridging embossing.

[0024] According to some implementations, one feature is that at least one feature (e.g., embossing enhancement feature) may include all of the following: (a) saddle, (b) offset alignment, and (c) bridging embossing.

[0025] According to some embodiments, one feature is that at least one feature (e.g., an embossing enhancement feature) may include an angled alignment of elongated embossings, wherein a first array of elongated embossings protrudes outward from a first side of the filter media sheet, and a second array of elongated embossings protrudes outward from a second side of the filter media sheet opposite to the first side.

[0026] According to some embodiments, one feature is that the filter media packaging utilizes only one of at least one of the following features (e.g., embossing enhancement feature) (selected from only one of the following: (a) saddle, (b) offset alignment, (c) bridging embossing, (d) angled alignment).

[0027] One feature is that the inlet flow surface may include a flat configuration, and the outlet flow surface may include a flat configuration, and preferably, the inlet flow surface and the outlet flow surface are coplanar.

[0028] One characteristic is that virtually all panels of the pleated filter media package can have elongated embossing formed therein.

[0029] One feature is that the filter media package can be incorporated into a filter cartridge, which includes a housing seal mounted to the pleated filter media package and an optional sealing support for mounting the housing seal.

[0030] Additional optional features when using a saddle One feature of using a saddle is that the elongated embossing can include a variable embossing profile comprising alternating peaks and valleys following a sinusoidal path with a repeating period. The period of the sinusoidal path can be offset between adjacent elongated embossings such that the peak of a first elongated embossing laterally coincides with the valley of a second elongated embossing adjacent to the first elongated embossing.

[0031] In the above features, the period can be shifted between 1 / 4 and 3 / 4, and more preferably shifted by 1 / 2 of the period.

[0032] An alternative feature when using a saddle is that the saddle can follow a repetitive cycle in a non-sinusoidal path.

[0033] In the above features, the elongated ridge can be between adjacent saddles, wherein the longitudinal span of the elongated ridge is at least 50% of the longitudinal span of the saddle, preferably between 50% and 300% of the longitudinal span of the saddle.

[0034] In the above features, the period of the non-sinusoidal path can be shifted between adjacent slender embossings, such that the peak of the first slender embossing coincides laterally with the valley of the second slender embossing adjacent to the first slender embossing.

[0035] When using a saddle, one feature is that the saddle provides a valley between adjacent peaks, wherein the elongated embossing at the valley can have a minimum depth between 25% and 75% of the maximum depth at the peak, and more preferably, the minimum depth is between 35% and 65% of the maximum depth.

[0036] When using a saddle, one feature is that the saddle provides valleys between adjacent peaks (and the elongated embossing can optionally vary in the lateral width span), wherein the minimum lateral width span is defined at the valley and the maximum lateral width span is defined at the peak, wherein the minimum lateral width span is between 50% and 100% of the maximum lateral width span, and if the lateral variation is present, the minimum lateral width span is more preferably between 60% and 85% of the maximum lateral width span.

[0037] One characteristic of using a saddle is that a saddle can be periodically set every 2 to 8 centimeters.

[0038] Additional optional features when using "offset alignment" When using offset alignment, one feature is that the offset alignment of the embossing positioning can be as follows: the unembossed / flat area extends a lateral span between adjacent elongated embossings on each panel, with the lateral midpoint between them located at 50% of the lateral span, wherein the first set of elongated embossings is joined at a position between 0% and 30% of the lateral span, and more preferably at a position between 5% and 20% of the lateral span.

[0039] In the above features, the lateral span of the unembossed / flat area can be at least 200% of the maximum width of the elongated embossing, wherein the lateral span of the unembossed / flat area is preferably between 200% and 600% of the maximum width of the elongated embossing.

[0040] Additional optional features when using "bridged embossing" When using bridging embossing, a characteristic is that the bridging embossing can extend laterally by more than 50% of the lateral span between adjacent members of the slender embossing, and preferably between 70% and 110% of the lateral span.

[0041] Of the above features, the bridging embossing preferably spans the unembossed / flat area of ​​the adjacent member connecting the elongated embossing.

[0042] When using bridging embossing, a characteristic is that at least 75% and preferably 90%-100% of the unembossed / flat areas have bridging embossing between adjacent members of the elongated embossing on all panels having elongated embossing.

[0043] One feature of using bridging embossing is that an arrangement can be provided in which, on each panel, the bridging embossing and the elongated embossing can project outward from opposite sides of the filter media sheet, respectively.

[0044] When using bridging embossing, a feature is that an arrangement can be provided in which all elongated embossings face the same direction in a pleated filter media package having a continuously alternating first panel and a second panel, wherein: (a) the elongated embossings on the first panel project outward from a first side of the filter media sheet, and the elongated embossings on the second panel project outward from a second side of the filter media sheet opposite to the first side; and (b) the bridging embossings on the first panel project outward from the second side of the filter media sheet, and the bridging embossings on the second panel project outward from the first side of the filter media sheet opposite to the second side.

[0045] One characteristic of using bridging embossing is that the elongated embossing on the first panel can contact the bridging embossing on the second panel adjacent to the first panel.

[0046] When using bridging embossing, one feature is that the bridging embossing can define the bridging width and the bridging depth, wherein: (a) the bridging width can be between 10% and 50% of the maximum width of the elongated embossing, and more preferably between 20% and 40% of the maximum width of the elongated embossing; and (b) the bridging depth can be between 10% and 50% of the maximum depth of the elongated embossing, and more preferably between 20% and 40% of the maximum depth of the elongated embossing.

[0047] One characteristic of bridging embossing is that paired gussets can seamlessly connect the bridging embossing with the slender embossing.

[0048] When using bridging embossing, one characteristic is that the bridging embossing can be elongated bridging embossing, which defines the bridging length / span between adjacent members of the elongated embossing, and the bridging width perpendicular to it, wherein the bridging width is between 1 mm and 3 mm, more preferably between 1 mm and 2 mm; and wherein the bridging length / span is between 4 mm and 36 mm, more preferably between 8 mm and 20 mm; and wherein the maximum bridging embossing depth is between 0.2 mm and 1.0 mm, more preferably between 0.3 mm and 0.8 mm.

[0049] One characteristic of using bridged embossing is that all panels, including those with slender embossing, can also include bridged embossing.

[0050] Additional optional features when using "angular alignment" When using angular alignment with elongated embossing, a characteristic is that the elongated embossing can protrude at an angle between 2 and 10 degrees relative to the pleats, more preferably between 3 and 8 degrees, and most preferably about 5 degrees.

[0051] One characteristic when using angular alignment with slender embossing is that slender embossing can extend linearly.

[0052] When using angular alignment with elongated embossing, a characteristic is that the elongated embossing is formed in the filter media sheet in a common tilt direction, wherein in a folded arrangement, the elongated embossing on adjacent panels is angled in opposite tilt directions.

[0053] Among the above features, at least one set of elongated embossed patterns can be formed parallel to each other in the filter media sheet.

[0054] Among the features described above, all the elongated embossed patterns can be formed parallel to each other in the filter media sheet.

[0055] When using angular alignment of elongated embossing, a feature is that a first array of elongated embossing can protrude outward from a first side of the filter media sheet, and a second array of elongated embossing can protrude outward from a second side of the filter media sheet opposite to the first side, wherein the embossing is angled with the common direction formed in the filter media sheet, such that, with the help of folds, the elongated embossing on adjacent panels is angled relative to each other in opposite directions.

[0056] When using angular alignment of elongated embossings, one feature is that each of the elongated embossings can terminate before reaching the fold, and linear scribing provides the fold.

[0057] In the above features, each elongated embossed pattern can be spaced apart from the pleats, thus stopping before reaching the pleats.

[0058] Other aspects and features of the invention Another aspect of the invention focuses on the use of a saddle feature (also known as variable height embossing). According to this aspect, the filter media package comprises: a plurality of panels of filter media extending laterally between an inlet flow surface and an outlet flow surface. The plurality of panels are arranged generally parallel, each panel having a first side and a second side opposite to the first side. "Generally parallel" means parallel or parallel within 2 degrees. A plurality of elongated embossings are formed in the panels and extend longitudinally between the inlet and outlet flow surfaces. The elongated embossings are laterally spaced and separated laterally by intermediate regions (e.g., the intermediate regions may be unembossed / flat regions), wherein each intermediate region lies between a corresponding pair of elongated embossings. Furthermore, a saddle is formed in the elongated embossings and raised relative to the intermediate regions.

[0059] Any one or more of the optional saddle features and optional filter media packaging features detailed above can be used in conjunction with aspects of the invention. Additional optional features are detailed below.

[0060] While this configuration may be advantageous in the non-pleated arrangements discussed herein, it is preferable that multiple panels are connected in a single continuous sheet folded into a pleated configuration, wherein the filter media package is a pleated filter media package.

[0061] One feature is that the elongated embossing can extend between 75% and 99% of the panel span between the inlet and outlet flow surfaces, and more preferably between 95% and 99% of the panel span between the inlet and outlet flow surfaces, wherein the panel extends between the inlet and outlet flow surfaces for a span between 7 and 45 cm, more preferably between 10 and 35 cm.

[0062] One feature is that the filter media sheet may include a blend of fibers comprising cellulose fibers and synthetic polymer fibers, wherein the blend of fibers comprises more than 50% cellulose fibers by weight percentage; and more preferably between 70%-90% cellulose fibers and 10%-30% synthetic polymer fibers; and most preferably between 75%-85% cellulose fibers and 15%-25% synthetic polymer fibers.

[0063] One feature is that the elongated embossing may include a maximum depth between 1.0 mm and 4.5 mm, more preferably between 1.0 mm and 2.0 mm, and most preferably between 1.3 mm and 1.6 mm.

[0064] One feature is that, within the inner area of ​​the filter media package, the lateral span of the intermediate area can be at least 200% of the lateral span of each elongated embossing, more preferably between 200% and 600%, and most preferably between 225% and 325%.

[0065] One feature is that, in the filter media package, all the elongated embossings can face the same direction, wherein the filter media package has a continuous alternating first panel and second panel, wherein the elongated embossings on the first panel protrude outward from a first side of the filter media sheet, and the elongated embossings on the second panel protrude outward from a second side of the filter media sheet opposite to the first side.

[0066] One feature is that the elongated embossing can include a variable embossing profile comprising alternating peaks and valleys following a sinusoidal path with a repeating period, wherein the period of the sinusoidal path is offset between adjacent elongated embossings such that the peak of the first elongated embossing laterally coincides with the valley of the second elongated embossing adjacent to the first elongated embossing.

[0067] An alternative feature is that the saddle follows a repetitive cycle in a non-sinusoidal path.

[0068] In the above features, the elongated ridge can be between adjacent saddles, wherein the longitudinal span of the elongated ridge is at least 50% of the longitudinal span of the saddle, preferably between 50% and 300% of the saddle span.

[0069] One of the features described above is that the period of the non-sinusoidal path can be shifted between adjacent slender embossings, such that the peak of the first slender embossing coincides laterally with the valley of the second slender embossing adjacent to the first slender embossing.

[0070] One feature is that the saddle provides a valley between adjacent peaks, wherein the elongated embossing can have a minimum depth at the valley between 25% and 75% of the maximum depth at the peak, and more preferably, the minimum depth is between 35% and 65% of the maximum depth.

[0071] One feature is that the saddle provides valleys between adjacent peaks, and the lateral width span of the elongated embossing can optionally vary, wherein the minimum lateral width span is defined at the valley and the maximum lateral width span is defined at the peak, wherein the minimum lateral width span can be between 50% and 100% of the maximum lateral width span, and if the lateral variation is desired, the minimum lateral width span can more preferably be between 60% and 85% of the maximum lateral width span.

[0072] One feature is that a saddle can be periodically installed every 2 to 8 centimeters.

[0073] One feature is that at least one additional feature (embossing reinforcement) can be used in conjunction with the saddle, the at least one feature being any one or more of the following: (a) offset alignment of embossing away from the midpoint of the intermediate region; (b) bridging embossing formed into the intermediate region; or (c) angular alignment of elongated embossing.

[0074] One characteristic is that virtually all panels of the filter media package have elongated embossing formed therein.

[0075] Another aspect of the invention focuses on the use of an "offset alignment" feature. According to this aspect, a filter media package includes multiple panels of filter media extending laterally between an inlet flow surface and an outlet flow surface. The multiple panels are arranged generally parallel, and each panel has a first side and a second side opposite to the first side. "Generally parallel" means parallel or parallel within 2 degrees. Multiple elongated embossings are formed in the panels and extend longitudinally between the inlet and outlet flow surfaces. The elongated embossings are laterally spaced and laterally separated by intermediate regions. Each intermediate region is located between a corresponding pair of elongated embossings. Furthermore, an offset alignment of the elongated embossings is provided, comprising a first set of elongated embossings on a first panel and a second set of elongated embossings on a second panel projecting in the same direction as the first set. The elongated embossings of the first set engage corresponding regions of the intermediate region of the second panel at a position offset from a laterally midpoint defined between corresponding adjacent embossings of corresponding regions of the intermediate region of the second panel.

[0076] Any one or more of the optional "offset alignment" feature and optional filter media packaging feature detailed above can be used in conjunction with aspects of the present invention. Additional optional features are detailed below.

[0077] While this configuration may be advantageous in the non-pleated arrangements discussed herein, it is preferable that multiple panels are connected in a single continuous sheet folded into a pleated configuration, wherein the filter media package is a pleated filter media package.

[0078] One characteristic is that virtually all panels of the filter media package have elongated embossing formed therein.

[0079] One feature is that the second set of elongated embossings joins the corresponding area of ​​the middle region of the first panel at a position offset from the lateral midpoint between the corresponding adjacent embossings of the corresponding area defined in the middle region of the first panel.

[0080] One feature is that the middle region extends a lateral span between adjacent elongated embossings on each panel, with the lateral midpoint thus located at 50% of the lateral span, wherein the first set of elongated embossings preferably joins at a position between 0% and 30% of the lateral span, and more preferably at a position between 5% and 20% of the lateral span.

[0081] One feature is that the lateral span of the non-middle area can be at least 200% of the maximum width of the slender embossing, and the lateral span of the middle area is preferably between 200% and 600% of the maximum width of the slender embossing.

[0082] One feature is that at least one additional feature (embossing enhancement) can be used in conjunction with offset alignment, the at least one feature being any one or more of the following: (a) a saddle formed into an elongated embossing; (b) a bridging embossing formed into an intermediate region; or (c) an angled alignment of the elongated embossing.

[0083] One feature is that the elongated embossing can extend between 75% and 99% of the panel span between the inlet and outlet flow surfaces, and more preferably between 95% and 99% of the panel span between the inlet and outlet flow surfaces, wherein the panel can extend between the inlet and outlet flow surfaces with a span between 7 and 45 cm, and more preferably between 10 and 35 cm.

[0084] One feature is that the filter media sheet comprises a blend of fibers including cellulose fibers and synthetic polymer fibers, wherein the blend of fibers comprises more than 50% cellulose fibers by weight percentage; and more preferably between 70%-90% cellulose fibers and 10%-30% synthetic polymer fibers; and most preferably between 75%-85% cellulose fibers and 15%-25% synthetic polymer fibers.

[0085] One feature is that the elongated embossing may include a maximum depth between 1.0 mm and 4.5 mm, more preferably between 1.0 mm and 2.0 mm, and most preferably between 1.3 mm and 1.6 mm.

[0086] One feature is that, within the inner area of ​​the filter media package, the lateral span of the intermediate area can be at least 200% of the lateral span of each elongated embossing, more preferably between 200% and 600%, and most preferably between 225% and 325%.

[0087] One characteristic is that, in the filter media packaging, all the elongated embossings can face the same direction. In the case where the filter media packaging has a continuously alternating first panel and a second panel, the elongated embossings on the first panel protrude outward from a first side of the filter media sheet, and the elongated embossings on the second panel protrude outward from a second side of the filter media sheet opposite to the first side.

[0088] Another aspect of the invention focuses on the use of a "bridging embossing" feature. According to this aspect, the filter media package includes: a plurality of panels of filter media extending laterally between an inlet flow surface and an outlet flow surface, wherein the plurality of panels are arranged substantially parallel, and each panel has a first side and a second side opposite to the first side. "Substantially parallel" means parallel or parallel within 2 degrees. A plurality of elongated embossings are formed in the panels and extend longitudinally between the inlet and outlet flow surfaces, wherein the elongated embossings are laterally spaced and laterally separated by intermediate regions, and wherein each intermediate region is between a corresponding pair of elongated embossings. Furthermore, bridging embossings are formed in the intermediate regions extending laterally between adjacent members of the elongated embossings.

[0089] Any one or more of the optional "bridging embossing" feature and optional filter media packaging feature detailed above can be used in conjunction with aspects of the present invention. Additional optional features are detailed below.

[0090] While this configuration may be advantageous in the non-pleated arrangements discussed herein, it is preferable that multiple panels are connected in a single continuous sheet folded into a pleated configuration, wherein the filter media package is a pleated filter media package.

[0091] One feature is that virtually all panels of the filter media package can have elongated embossing formed therein.

[0092] One feature is that the elongated embossing can extend between 75% and 99% of the panel span between the inlet and outlet flow surfaces, and more preferably between 95% and 99% of the panel span between the inlet and outlet flow surfaces, and the panel can extend between the inlet and outlet flow surfaces with a span between 7 and 45 cm, more preferably between 10 and 35 cm.

[0093] One feature is that the filter media sheet may include a blend of fibers comprising cellulose fibers and synthetic polymer fibers, wherein the blend of fibers comprises more than 50% cellulose fibers by weight percentage; and more preferably between 70%-90% cellulose fibers and 10%-30% synthetic polymer fibers; and most preferably between 75%-85% cellulose fibers and 15%-25% synthetic polymer fibers.

[0094] One feature is that the elongated embossing may include a maximum depth between 1.0 mm and 4.5 mm, more preferably between 1.0 mm and 2.0 mm, and most preferably between 1.3 mm and 1.6 mm.

[0095] One feature is that, within the inner area of ​​the filter media package, the lateral span of the intermediate area can be at least 200% of the lateral span of each elongated embossing, more preferably between 200% and 600%, and most preferably between 225% and 325%.

[0096] One characteristic is that, in the filter media packaging, all the elongated embossings can face the same direction. In the case where the filter media packaging has a continuously alternating first panel and a second panel, the elongated embossings on the first panel protrude outward from a first side of the filter media sheet, and the elongated embossings on the second panel protrude outward from a second side of the filter media sheet opposite to the first side.

[0097] One feature is that at least one feature (embossing enhancement feature) can be used in conjunction with bridging embossing, which can be any one or more of the following: (a) a saddle formed in an elongated embossing; (b) an offset alignment of embossing away from the midpoint of the intermediate region; or (c) an angular alignment of elongated embossing.

[0098] One feature is that the bridging embossing can extend laterally between adjacent members of the slender embossing by more than 50% of the lateral span, and preferably between 70% and 110% of the lateral span, and most preferably the bridging embossing completely spans the middle area, connecting the adjacent members of the slender embossing.

[0099] One characteristic is that bridging embossing can include at least 75%, preferably 90%-100%, of the intermediate region between adjacent members of the elongated embossing, and most or all panels have elongated embossing.

[0100] One feature is that on each panel, bridging embossing and elongated embossing can protrude outward from opposite sides of the filter media sheet, respectively.

[0101] One feature is that, in the pleated filter media package, all the elongated embossings can face the same direction, wherein the filter media package has a continuously alternating first panel and a second panel, wherein: (a) the elongated embossings on the first panel protrude outward from a first side of the filter media sheet, and the elongated embossings on the second panel protrude outward from a second side of the filter media sheet opposite to the first side; and (b) the bridging embossings on the first panel protrude outward from the second side of the filter media sheet, and the bridging embossings on the second panel protrude outward from the first side of the filter media sheet opposite to the second side.

[0102] One feature is that the elongated embossing on the first panel can contact the bridging embossing of the second panel adjacent to the first panel.

[0103] One feature is that the bridging embossing can define the bridging width and the bridging depth, wherein: (a) the bridging width is between 10% and 50% of the maximum width of the elongated embossing, and more preferably between 20% and 40% of the maximum width of the elongated embossing; and the bridging depth is between 10% and 50% of the maximum depth of the elongated embossing, and more preferably between 20% and 40% of the maximum depth of the elongated embossing.

[0104] One feature is that a pair of formed gusset plates connect the bridging embossing and the slender embossing in one piece.

[0105] One feature is that the bridging embossing can be an elongated bridging embossing, which defines the bridging length / span between adjacent members of the elongated embossing, and the bridging width perpendicular to it. The bridging width is between 1 mm and 3 mm, more preferably between 1 mm and 2 mm; and wherein the bridging length / span is between 4 mm and 36 mm, more preferably between 8 mm and 20 mm; and wherein the maximum bridging embossing depth is between 0.2 mm and 1.0 mm, more preferably between 0.3 mm and 0.8 mm.

[0106] One feature is that all panels, including those with slender embossing, also include bridged embossing.

[0107] Another aspect of the invention focuses on the use of an "angular alignment" feature. According to this aspect, the filter media package includes: a plurality of panels of filter media extending laterally between an inlet flow surface and an outlet flow surface, wherein the plurality of panels are arranged substantially parallel, and each panel has a first side and a second side opposite to the first side. "Substantially parallel" means parallel or parallel within 2 degrees. A plurality of elongated embossings are formed in the panels and extend longitudinally between the inlet and outlet flow surfaces, wherein the elongated embossings are laterally spaced and laterally separated by intermediate regions, each intermediate region being between a corresponding pair of elongated embossings. Furthermore, an angular alignment is provided to the elongated embossings, wherein the elongated embossings extend at an oblique angle relative to the pleats and provide intermittent contact positions with each other.

[0108] Any one or more of the optional "angled alignment" feature and optional filter media packaging feature detailed above can be used in conjunction with aspects of the present invention. Additional optional features are detailed below.

[0109] While this configuration may be advantageous in the non-pleated arrangements discussed herein, it is preferable that multiple panels are connected in a single continuous sheet folded into a pleated configuration, wherein the filter media package is a pleated filter media package.

[0110] One feature is that virtually all panels of the filter media package can have elongated embossing formed therein.

[0111] One feature is that the elongated embossing can extend between 75% and 99% of the panel span between the inlet and outlet flow surfaces, and more preferably between 95% and 99% of the panel span between the inlet and outlet flow surfaces, wherein the panel can extend between the inlet and outlet flow surfaces with a span between 7 and 45 cm, and more preferably between 10 and 35 cm.

[0112] One feature is that the filter media sheet may include a blend of fibers comprising cellulose fibers and synthetic polymer fibers, wherein the blend of fibers comprises more than 50% cellulose fibers by weight percentage; and more preferably between 70%-90% cellulose fibers and 10%-30% synthetic polymer fibers; and most preferably between 75%-85% cellulose fibers and 15%-25% synthetic polymer fibers.

[0113] One feature is that the elongated embossing may include a maximum depth between 1.0 mm and 4.5 mm, more preferably between 1.0 mm and 2.0 mm, and most preferably between 1.3 mm and 1.6 mm.

[0114] One feature is that, within the inner area of ​​the filter media package, the lateral span of the intermediate area can be at least 200% of the lateral span of each elongated embossing, more preferably between 200% and 600%, and most preferably between 225% and 325%.

[0115] One feature is that at least one feature (embossing enhancement feature) can be used in conjunction with an angled alignment, the at least one feature being any one or more of the following: (a) a saddle formed as an elongated embossing; (b) an offset alignment of embossing away from the midpoint of the intermediate region; or (c) a bridging embossing formed into the intermediate region.

[0116] One feature is that the elongated embossing can protrude at an angle between 2 and 10 degrees relative to the pleats, more preferably between 3 and 8 degrees, and most preferably about 5 degrees.

[0117] One characteristic is that slender embossed patterns can extend linearly.

[0118] One feature is that elongated embossing is formed in the filter media sheet in a common inclined direction, wherein in a folded arrangement, the elongated embossing on adjacent panels is angled in opposite inclined directions.

[0119] One characteristic is that, in a folded arrangement, the slender embossed patterns can be spaced apart from the folds.

[0120] One feature is that at least one set of elongated embossed patterns can be formed parallel to each other in the filter media sheet.

[0121] One feature is that all the elongated embossed patterns can be formed parallel to each other in the filter media sheet.

[0122] One feature is that the first array of elongated embossings protrudes outward from a first side of the filter media sheet, and the second array of elongated embossings protrudes outward from a second side of the filter media sheet opposite to the first side, and wherein the embossings are angled with a common direction formed in the filter media sheet, such that when folded on top of each other, the elongated embossings on adjacent panels are angled relative to each other in opposite directions.

[0123] One feature is that each of the elongated embossed sections terminates at a pleated section without providing a pleated filter media package, and that linear scribing provides the pleated section.

[0124] One feature is that each elongated embossed piece can be spaced apart from the pleats, thus stopping before reaching the pleats.

[0125] The following describes additional alternative wording aspects, which may be used alone or in combination with any feature or the foregoing aspects in multiple aspects / features.

[0126] One aspect relates to a media package for a filter element, the media package comprising media material panels supported face-to-face, each media panel comprising a plurality of embossings extending across the width of the media panel in a parallel and uniformly spaced relationship and opening in the same direction. At least some of the embossings vary in height from the surface of the media panel along the length of the embossings.

[0127] In the above aspects, the embossing may have a common width at the base of the embossing along the surface of the media panel, or all or some of the embossing may have different widths.

[0128] Similarly, in the above aspects, the embossing can be arranged on the medium panel such that the height of the embossing varies sinusoidally along the length of the embossing.

[0129] Similarly, in the above aspects, adjacent embossings can also be arranged such that the peak of one embossing is offset longitudinally from the peak of the adjacent embossing along the length of the embossing. In one aspect, the peak of one embossing is offset longitudinally from the peak of the adjacent embossing along the length of the embossing by no more than 25%.

[0130] On the other hand, a media package for a filter element is provided, the media package comprising media material panels supported face-to-face with each other, each media panel comprising a plurality of embossings extending across the width of the media panel in a parallel and uniformly spaced relationship and opening in the same direction, the media panels being arranged relative to each other such that the lateral offset of an embossing on one media panel from the embossing on an adjacent media panel does not exceed 25% of the distance between adjacent embossings on one panel.

[0131] On the other hand, a media package for a filter element is disclosed, comprising media material panels supported face-to-face, each media panel including a plurality of embossings extending parallel to each other and uniformly spaced along the width of the media panel and opening in the same direction, the media panels being arranged relative to each other such that an embossing on one media panel is located between embossings on adjacent media panels. Support bridges are also included on the media panels, extending at least a portion of a lateral distance between at least some of the embossings on at least one media panel. The support bridges may include a plurality of support bridges on the media panels extending laterally between adjacent embossings on the media panels.

[0132] On the other hand, a media package for a filter element is disclosed, comprising media material panels supported face-to-face, each media panel including a plurality of embossings extending across the width of the media panel in a parallel and uniformly spaced relationship and opening in the same direction, wherein the embossings project at an angle to the opposite side edges of the media panel. The media panels are arranged relative to each other such that the embossing on one media panel is positioned to engage with the embossing on the adjacent media panel.

[0133] Other aspects, objects, and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings. Attached Figure Description

[0134] Several aspects of the invention are illustrated in conjunction with the accompanying drawings, which are included and form part of this specification, and serve to explain the principles of the invention. In the drawings: Figure 1 This is a perspective view of a pleated filter media package with different embossing heights according to different embodiments of the present invention; Figure 2 It is used for manufacturing Figure 1 An enlarged stereoscopic view of a portion of the embossed and pleated sheet of the filter media packaging; Figure 3 yes Figure 2 A perspective view of a portion of a single embossed panel, shown for better detail; Figure 4yes Figure 3 End view of the filter media panel section; Figure 5 yes Figure 3 Side view of the filter media panel section; Figure 6 , 6A 6B and 6B are respectively Figure 1 The side view, end view and sectional perspective view of a portion of the filter media packaging, but the height embossing remains unchanged for comparison with embodiments of the present invention; Figure 7 , 7A 7B and 7B are respectively Figure 1 Side view, end view, and sectional perspective view of a portion of the filter media packaging, in order to... Figure 6 , 6A Compared with 6B, the variation in embossing height is further demonstrated; Figure 8 Is through used for Figure 1 The top surface end profile view of the saddle for the "Extrusion" option of the variable height embossing implementation scheme; Figure 9 Is through used for Figure 1 The top surface end profile view of the saddle for the "cutting" option of the variable height embossing implementation scheme.

[0135] Figure 10 Is through used for Figure 1 The top surface end profile view of the saddle for the "translation" option of the variable height embossing implementation scheme; Figure 11 Is using Figure 10 A plan view of a portion of the filter media sheet with translation options; Figure 12 It is along Figure 1 The side profile of the panel of the filter media package shows the sinusoidal path of the embossing, which has a repeating period and a 1 / 2 offset of the period between adjacent embossings (e.g., in a parallel interval relationship). Figure 13 It is along a path similar to Figure 12 The side profile of the panel of the filter media package has adjacent embossings, but according to the alternative option, it also has embossings that follow a sinusoidal path and repeating cycle, but with a cycle offset of less than 1 / 2 of the cycle between adjacent embossings (e.g., in a parallel spacing relationship). Figure 14 It is along a path similar to Figure 12 The side profile of the adjacent embossed panels of the filter media packaging panel, but according to the ratio Figure 12An alternative with a longer period of length, and also with a sinusoidal path of embossing that has a repeating period and a 1 / 2 offset of the period between adjacent embossings (e.g., in a parallel interval relationship); Figure 15 It is similar to Figure 12 The side profile of adjacent embossed patterns along the panel of the filter media package; however, according to an alternative option with embossing following a non-sinusoidal path, the periodic saddles are spaced apart along the repeating cycle, and the cycles of adjacent embossing patterns may or may not be offset (in... Figure 15 The offset is not shown in the image because the adjacent embossed saddles are aligned from the side view. Figure 16 This is a cross-sectional view taken through the transversely embossed filter media package according to an offset alignment embodiment of the invention, showing an offset embossing alignment less than half the spacing between the embossings of adjacent panels (and the dashed lines envision an idealized potential deflection of the flat areas of the filter media sheet in the folded package and subjected to compressive pressure). Figure 17 Is with Figure 16 The sectional view is the same as the sectional view, but for comparison Figure 16 In one embodiment of the invention, there is an offset embossing alignment at half the distance between the embossings of adjacent panels (and the dashed lines take into account the idealized potential deflection of the flat area of ​​the filter media sheet in the folded package and subject to extrusion pressure). Figure 18 It is used for manufacturing Figure 16 An enlarged perspective view of a portion of the embossed and pleated sheet of the filter media packaging for the offset alignment implementation scheme; Figure 19 Is using Figure 18 An assembled perspective view of the embossed and pleated sheet filter media packaging, through which a section can be extracted. Figure 16 The cross-section; Figure 20 This is a perspective view of a portion of a filter media sheet having bridging embossing arranged between longitudinal embossings according to an embodiment of the present invention; Figure 21 It is a cross-sectional view taken laterally through the longitudinal embossing of the filter media package (and the dashed lines in it envision an idealized potential deflection of the flat area of ​​the filter media sheet in the folded package and subject to extrusion pressure). Figure 22 It is perpendicular to Figure 21 A cross-sectional view of the filter media package taken from the side to show the bridging embossing features; Figure 23 It is used to manufacture filter media packaging according to the bridging embossing scheme. Figure 20-22A magnified stereoscopic view of a portion of the embossed and pleated sheet with bridging embossing features; Figure 23A yes Figure 23 An enlarged view of the circular portion; Figure 24 It has the characteristics of Figure 23 A perspective view of a transversely extending, bridged, embossed, pleated filter media package made of filter media sheets. Figure 25 This is a plan view of a portion of a filter media sheet with angled embossing according to an embodiment of the present invention, wherein the two edges of the portion shown are parallel to the fold tip and the two edges are perpendicular to the fold tip, so as to show the angle of the elongated embossing relative to the fold tip. Figure 26 yes Figure 25 A three-dimensional view of the filter media sheet portion; Figure 27 yes Figure 25 End view of the filter media sheet portion; Figure 28 It is based on Figure 25 The construction of the angled embossing scheme includes a cross-sectional view of the angled embossed filter media package (a flow inlet view with a cross-section taken parallel to the inlet surface); Figure 29 It is a filter media packaging similar to the angled embossing implementation scheme. Figure 28 Another cross-sectional view of the filter media packaging, but for a perspective view of the angled embossed features, the cross-section is taken along an inclined plane relative to the inlet surface; Figure 30 It is used according to Figure 25 A filter media package consisting of filter media sheets assembled with angled embossing; Figure 31 It is used for manufacturing Figure 30 An enlarged stereoscopic view of a portion of the embossed and pleated sheet of the filter media packaging; Figure 32 Is Figure 30 Close-up perspective views of the folded tips used at the inlet and outlet faces, where the folded tips are constructed with a single scribing (it should be understood that the folded tips at the inlet and outlet faces can be constructed identically; and this folding and crease construction can also be used for other similar folds). Figure 2 Implementation plans 18, 23, 36, and 38; Figure 33 This is an enlarged perspective view of the pleated tip region of the filter media sheet portion, which is shown as being used for... Figure 18Another embodiment of the type with offset alignment, which in this case uses two scribing lines (and can also be used in other similar cases). Figure 2 , 23 Implementation plans for 31, 36 and 38); Figure 34 Is it used as Figure 33 An enlarged perspective view of the pleated tip area of ​​the filter media sheet with two crisscross lines (it should be understood that the pleated tip area with folds and creases at both the inlet and outlet surfaces can be constructed to be identical).

[0136] Figure 35 is a filter media package assembled with filter media sheets having variable height and offset embossing according to another embodiment of the present invention, using filter media sheets with variable height and offset embossing according to the combined feature embodiment; Figure 36 This is an enlarged perspective view of a portion of the embossed and pleated sheet used to manufacture the filter media packaging of Figure 35; Figure 37 It is a filter media package assembled using filter media sheets with variable height and offset embossing according to another embodiment of the invention, and also includes bridging embossing according to another embodiment of combined features; Figure 38 It is used for manufacturing Figure 37 An enlarged stereoscopic view of a portion of the embossed and pleated sheet of the filter media packaging; Figure 39 yes Figure 18 The side profile and cross-sectional view of the filter media sheet with offset alignment embossing used (but shown in a flat form rather than partially folded), in which the filter media sheet uses a single scribing line for the folded portion (and this scribing / folding feature can also be used for other similar...). Figure 2 , 23 , 31, 36 and 38); and Figure 40 yes Figure 39 A close-up perspective view of a portion of the filter media sheet, where the pleats are folded by a single scribing line when folded, and once folded, the pleats resemble... Figure 32 As shown in the image.

[0137] While the invention will be described in conjunction with certain preferred embodiments, it is not intended to limit it to those embodiments. Rather, it is intended to cover all alternatives, modifications, and equivalents included within the spirit and scope of the invention as defined by the appended claims. Detailed Implementation

[0138] Before proceeding to the various illustrated implementation schemes, a global overview roadmap of the different schemes will be provided. (Already...) Figure 1-38Different illustrated embodiments of the invention are depicted in various filter media packages 10, 110, 210, 310, 410, and 510, each of which may relate to reducing clogging, providing structural integrity, or otherwise improving airflow. For better detail, these packages 10, 110, 210, 310, 410, and 510 are shown with a relatively limited number of pleats; however, it should be understood that more pleats can typically be used in larger / wider filter media packages. The actual number of pleats and package size depend on the specific filtration application.

[0139] Each illustrated embodiment shares common features such that the same reference numerals will be used for common features between different embodiments. For example, each filter media package 10, 110, 210, 310, 410, 510 includes a filter media sheet 12 folded along a pleat 14 at an inlet flow surface 16 and a filter media sheet 12 folded along a pleat 14 at an outlet flow surface 18. The pleat 14 provides a plurality of folds 19 having panels 20 (panels 20 may also be referred to as “pleated panels”) extending between the inlet flow surface 16 and the outlet flow surface 18.

[0140] It can be seen and understood that the inlet flow surface 16 and the outlet flow surface 18 can be configured to be substantially the same as the set of fold tips 22 provided by the fold 14 at one or the other end, and therefore can be interchangeable (e.g., such that the inlet surface 16 can be used at the outlet surface 18, and the outlet surface 18 can be used as the inlet surface 16 in use). Thus, another way of expressing this is that the inlet and outlet flow surfaces are opposite flow surfaces, wherein in use, one surface is selected to be the inlet flow surface, and the other is used as the outlet flow surface.

[0141] Typically, the assembly of pleated tips 22 is aligned with the planes of the inlet and outlet flow surfaces 16, 18 for the respective filter media packages 10, 110, 210, 310, 410, 510, as shown. However, either or both of the inlet flow surface 16 and the outlet flow surface 18 may be inclined or curved (e.g., if the pleated panels 20 do not have equal dimensions, or if the filter media package is bent when mounted to a frame or sealing system).

[0142] Each of the illustrated embodiments commonly includes a plurality of elongated embossings 24 formed in the filter media sheet 12. The elongated embossings 24 extend longitudinally between the inlet flow surface 16 and the outlet flow surface 18. The elongated embossings 24 are also laterally spaced and separated laterally by unembossed / flat regions 26 (which may also be more generally referred to as “intermediate regions”).

[0143] Unembossed / flattened areas 26 correspond to the flat and / or unembossed areas of the filter media sheet 12 (i.e., the areas between adjacent elongated embossings 24) within the filter media sheet 12. Typically, the filter media sheet 12 is fed from a storage roll / reel to a roll press or molding press for embossing, and through unembossed / flattened areas 26, which refer to those portions not formed in the areas between the elongated embossings 24 during embossing.

[0144] With this arrangement, the inlet flow channel 28 is created along one side of the filter media sheet along the unembossed / flat area between the elongated embossings 24 and / or within the grooved channel 31 defined within the elongated embossings 24; and the outlet flow channel 29 is created along the opposite side of the filter media sheet 12 along the unembossed / flat area between the elongated embossings 24 and / or within the grooved channel 31 defined within the elongated embossings 24.

[0145] With this arrangement of the inlet flow channel 28 and the outlet flow channel 29, unfiltered airflow can enter through the inlet flow surface 16 and axially through the inlet flow channel 28. Axial means perpendicular to the inlet flow surface 16, or primarily in the axial direction (therefore, the term "axial" is broad enough to encompass...). Figure 25-31 (The embossing in the middle is angled). Airflow enters the interior of the filter media package through the axial inflow inlet flow surface 16. Unfiltered airflow passes laterally through the pores of the filter media sheet 12. These pores are created by the matrix of filter media fibers therein, in which the filter media sheet 12 captures unwanted particles and contaminants on the upstream side and within the matrix of filter media fibers, thereby filtering the airflow. Therefore, the airflow leaves the filter media sheet 12 in a filtered state and enters the outlet flow channel 29, thereby creating a filtered airflow in the outlet flow channel 29 that passes axially toward the outlet flow surface 18, and the filtered airflow leaves the outlet flow surface 18 in a cleaner state than the air entering the inlet flow surface 16.

[0146] In addition to the elongated embossing 24, each of the filter media packages 10, 110, 210, 310, 410, and 510 also includes at least one feature (also referred to as embossing reinforcement) comprising any one or more of the following: (a) a saddle 30 formed into the elongated embossing 26, the saddle 30 being raised relative to the unembossed / flat region 26; or (b) an offset alignment 32 of the elongated embossing, the offset alignment 32 avoiding nesting and offset from the midpoint of the unembossed / flat region 26; or (c) a bridging embossing 34 formed into the unembossed / flat region 26, the bridging embossing 34 extending laterally between adjacent members of the elongated embossing 24; or (d) an angled alignment 36 of the elongated embossing 24, wherein the elongated embossing 34 extends at an angle relative to the pleat 14 (e.g., the pleat tip 24).

[0147] Any one or more of the features (e.g., saddle 30, offset alignment 32, bridging embossing 34, or angled alignment 36) enhance the functionality of the elongated embossing 26 by providing any one or more of the following functions: (a) lateral bridging / beam strength between elongated embossings, (b) panel / embossing stiffness, (c) intermittent contact points, or (d) stiffness / relaxation resistance of the pressing features in the filter media sheet.

[0148] At this point in the discussion, it can be seen that some implementations may include only one of these features. For example, only saddle 30 in Figure 1-5 In 7-15; only the offset alignment 32 is in Figure 16 , 18 -19; only bridging embossing 34 in Figure 20-24 In the middle; and only tilted to align with 36. Figure 25-33 As shown in the figures. Additionally, some embodiments may include two or more of these features, and sometimes all of them are included. For example, Figures 35-36 show a filter media package 410 having at least one feature including two of the following: a saddle 30 and an offset alignment 32. As another example shown, Figures 37-38 A filter media package 510 is shown, which has at least one of the following three features: saddle 30, offset alignment (part) 32, and bridging embossing 34.

[0149] Based on the foregoing, as used throughout this application, "or" should also be readily understood to mean "inclusive or," particularly with respect to the existence of at least one feature. Unless there is an explicit statement to the contrary for the statement (e.g., a or b, but not both indicating the opposite) or it is obvious from the context, "or" means "inclusive or" rather than "exclusive or." For example, feature / condition A, B, or C is satisfied by any of the following: A is true (or exists) and B and C are false (or do not exist); B is true (or exists) and A and C are false (or do not exist); C is true (or exists) and A and B are false (or do not exist); any combination of two from the group of A, B, and C is true (or exists) and the remaining feature / condition is false (or does not exist); or a combination of each of A, B, and C is true (or exists) without any false (or non-existent) feature / condition.

[0150] For example, the use of "or" to include at least one of the following features: (a) saddle 30, or (b) offset alignment 32, or (c) bridging embossing 34, or angled (d) alignment 36 is sufficiently wide to cover any and all of the fifteen distinct different embodiments AO presented in Table 1 below (including five shown embodiments and ten other embodiments not shown), wherein each row item indicates the presence or absence of each corresponding feature of that embodiment. Furthermore, it should be apparent that the use of "included" allows for the inclusion of optional additional features, provided that at least one of the listed features is included, which can further enhance the anti-clogging or flow characteristic benefits.

[0151] Table 1. Different combinations of features in the implementation scheme

[0152] Before moving on to further details of structured enhancement / anti-clogging features, for those that can be implemented in, such as Figure 1-38 Other common features used in the embodiments shown in the various filter media packages 10, 110, 210, 310, 410, and 510 will continue to be of particular interest.

[0153] To maintain pleat separation and for orderly flow, the elongated embossing 24 preferably extends a longitudinal span 40 between 75% and 99% of the span 42 of the panel 20 between the inlet and outlet flow surfaces (e.g., the distance between the pleat tips 22 at the opposite inlet / outlet surfaces 16, 18). More preferably, the embossing longitudinal span 40 is between 95% and 99% of the span 44 of the panel between the inlet flow surface 16 and the outlet flow surface 18.

[0154] In the first three embodiments, when the elongated embossing 24 extends perpendicularly relative to the pleated portion 14, the longitudinal span 40 of the embossing is equal to the actual length of the embossing (this span and measurement includes the tapered end 44). However, if the embossing is angled as in the angled alignment 36, then in order to... Figure 31 For the purpose of comparing the pleated panel span 42 shown, the embossing span 40 is measured perpendicular to the pleat tip 22. Therefore, as used herein, the embossing longitudinal span 40 refers to the percentage of embossing coverage between the pleat tips 22 (e.g., the distance between the planes generated by the inlet and outlet flow surfaces 16, assuming a more typical rectangular cube design as shown).

[0155] While in some embodiments of the invention the embossing may extend through the pleat tip 22 and continuously through the pleat fold, this is not preferred; and as shown, the embossing stops before reaching the pleat tip 22. Thus, the construction and arrangement of the elongated embossing 24 can be maximized without interfering with the formation of pleats and inlet / outlet flow surfaces.

[0156] Furthermore, as shown in the figure, the slender embossed 24 may have a tapered end 44 near the inlet surface 16 and the outlet surface 18. The tapered end 44 provides a widened inlet and outlet area for airflow to enhance airflow characteristics. The tapered end 44 facilitates easier folding and prevents the media sheet from tearing near the folds.

[0157] Between the tapered ends 44, the elongated embossing 24 can have a constant maximum depth 54 (i.e., a constant depth other than the depth interrupted by the saddle 30, if used), which, when pressed into the filter media packages 10, 110, 210, 310, 410, 510, provides a parallel relationship between the pleated panels 20 in conjunction with the folds. Some variations in parallelism can be envisioned, hence the term "generally parallel" is sometimes used in the specification, because the pleated panels 20 extend generally parallel to each other (e.g., if the embossing depth is slightly shallower near one flow surface compared to the other). Therefore, as used herein, "generally parallel" means and includes parallelism and parallelism within 2 degrees.

[0158] Another common feature that can be adopted, as shown in the figure, is to provide a crease area 46 without elongated embossing 24, so as to facilitate easier folding of the pleats 19. A crease area 46 without embossing is provided, which extends laterally between the opposite edges 48 of the filter media sheet 12 (see, for example...). Figure 33 and 34 (Enlarged view). The crease region 46 has a width parallel to the opposite edge spanning the crease region span 52, which is between 0.1 cm and 3.0 cm, more preferably between 0.2 cm and 1.0 cm (e.g., ...). Figure 33 As shown, and this span 52 can be measured most easily and optimally when the filter media sheet is in an unfolded state (such as on a flat surface).

[0159] To provide the folded portion, the filter media sheet can be simply folded at the location of the folded area 46 without regularly spaced scribe lines to provide any filter media package 10, 110, 210, 310, 410, 510. The folded area 46 does not have the same bridging strength as the remainder of the panel with embossing that provides bridging strength. However, using scribe lines where the folding position can be predetermined may be advantageous, making folding easier and providing better folding consistency.

[0160] Therefore, at least one crisscross 50 can be formed in each crease area 46, thereby facilitating the folded portion 14. For example, in the case of... Figure 32 , 39 -40 and Figures 33-34When making comparisons, one or two scribing lines 50 may be used. One or two scribing lines 50 for each fold 14 / fold tip 22 may be used in any filter media package 10, 110, 210, 310, 410, 510.

[0161] Regarding the "crease area", and in Figure 33 (Two lines for each fold) and Figure 39 As best shown in the single crisscross for each fold, the elongated embossing 24 is located outside the crease region 46. The elongated embossing 24 tapers towards the opposite end of the elongated embossing 24 and terminates at the crease region 46 (see also, for example, see also). Figure 1 , 2 18, 19, 23, 24, 30, 31 show the embossing not extending into the folded portion 14 of the crease area 46.

[0162] As described above, the scribe line 50 can be used to predetermine and better provide the fold 14 and fold tip 22. For example, in some embodiments, a scribe line 50 may be formed in the crease area 46 (as in...). Figures 39-40 (in the middle), or two lines 50 are formed in the crease area 46 (in the middle). Figures 32-34 These lines are arranged in a spaced-out relationship (e.g., parallel).

[0163] like Figure 34 As shown, each fold can have two parallel scribing lines to predetermine the fold position and help configure the width of the fold tip 22. This can result in a flatter fold tip profile that can be considered flat.

[0164] Alternatively, when using a single scribing line 50, it can be positioned at or near the apex of the intended fold tip 22, providing a single, specific targeted weakening / pre-folding area where folding can be more easily achieved, such as... Figure 40 As shown. Figure 32 As shown, once fully folded, this can also result in a more rounded fold tip 22 profile.

[0165] For example, the single or double scribbles 50 can optionally be formed simultaneously with the embossing 20, and have a shallow depth between 10-60% of the thickness of the filter medium sheet 12 calipers, and a width between 0.5 mm and 1 mm.

[0166] While some embodiments may envision intermittent or intermittent embossing as elongated embossing 24, preferably, all elongated embossing 24 is uninterrupted and extends continuously across the entire span between the crease regions 46, such as Figure 1-38The filter media packages 10, 110, 210, 310, and 410 are shown. Advantageously, the continuity of the elongated embossing 24 better maintains bridging strength and spacing, and avoids flat areas in the filter media sheet that provide weakening or pivoting regions. Regarding the features of the saddle 30 used in some embodiments, the saddle 30 avoids interruption and maintains the continuous extension of the elongated embossing because even at the saddle, the elongated embossing is formed and raised relative to the unembossed / flat area 26 of the filter media sheet 12.

[0167] The implementation scheme is particularly advantageous for deeper filter media packaging, which is more susceptible to clogging issues, whereby the elongated embossing 24 and other features can maintain a more orderly flow. For example, the pleated panel 20 can extend a span 42 between the inlet flow surface 16 and the outlet flow surface 18, the span 42 being between 7 cm and 45 cm, and more preferably between 10 cm and 35 cm.

[0168] The filter media sheet 12 may include a filter media containing fibers. For example, the filter media sheet 12 may include any one or more of the following: cellulose fibers, synthetic polymer fibers, or glass fibers.

[0169] For example, filter media sheet 12 often includes a blend of fibers comprising cellulose fibers and synthetic polymer fibers.

[0170] Further discussion of cellulose / synthetic filter media is warranted at this time. Cellulose-based filter media are less prone to coagulation and fixation (i.e., more easily relaxed) compared to primarily thermoplastic polymer media, which are better suited for heat setting and maintaining embossed and pleated panel shapes. Additionally, many typical thermoplastic polymer filter media fibers have greater stretching capacity than cellulose filter media fibers. Therefore, thermoplastic polymer filter media fibers can offer greater embossing depth. However, cellulose fibers offer other benefits and are desirable for many filtration applications.

[0171] Therefore, while the combination of elongated embossing 24 with at least one additional structural feature (e.g., saddle 30, offset alignment 32, bridging embossing 34, or angled alignment 36) will primarily enhance thermoplastic polymer media, these features are particularly useful and advantageous for primary cellulose filter media. For example, in filter media sheet 12, the blend of cellulose fibers and polymer fibers comprises more than 50% cellulose fibers by weight; and more preferably between 70-90% cellulose fibers and 10-30% synthetic polymer fibers; and most preferably between 75-85% cellulose fibers and 15-25% synthetic polymer fibers (which may sometimes be referred to as an 80 / 20 cellulose media).

[0172] In many designs that primarily utilize thermoplastic polymer media, alternating flat pleated panels and embossed panels can be more readily used, as illustrated in some embodiments of U.S. Patent Publication US2022 / 0096985 A1 by Tate et al. This is due to the heat-set strength of thermoplastic fibers. Because primarily cellulose fiber media have low tensile strength and are prone to tearing, the depth of such primarily cellulose-based embodiments is ideally smaller, such that, preferably, elongated embossing 24 is applied to most or all of the filter media packaging pleated panels 20 to maximize the pleat spacing using the depth of embossing 24, which can be achieved without tearing due to embossing formation.

[0173] With this in mind, in the embodiments, the elongated embossing 24 includes a maximum depth 54 between 1.0 mm and 4.5 mm, with the higher end generally being more suitable for filter media blends that are primarily polymer-based. More preferably, the maximum embossing depth is between 1.0 mm and 2.0 mm, and most preferably between 1.3 mm and 1.6 mm (especially for primarily cellulose blends, such as 80 / 20 cellulose media).

[0174] While additional adhesive carriers may be used in some embodiments, such adhesives increase cost, weight, and clog the filter media, reducing filtration capacity. Therefore, when the elongated embossing 24 is combined with at least one additional structural feature (e.g., saddle 30, offset alignment 32, bridging embossing 34, or angled alignment 36), preferably, no adhesive is applied inside any pleated filter media packages 10, 110, 210, 310, 410, 510 between the panels 20 of the filter media sheet 12. However, adhesives such as sealants are typically applied to and close to the periphery of the filter media package, for example along the side edge 48 to facilitate closure of the sides of the flute, or applied to the flow surface (e.g., hot-melt support beads are applied to the flow surface), but none of these are considered "inside the pleated filter media package" because they are along the periphery.

[0175] The slender embossed pattern 24 has a lateral span 56, which can vary between embodiments, or even within the same embodiment, for example, in... Figure 10 and 11The lateral span 56 of the embossed pattern can be measured perpendicularly to the longitudinal extension of the elongated embossed pattern 24, as shown in the saddle area. While not limited to this, as wider embossing is possible, in many applications and embodiments, the lateral span 56 of the elongated embossed pattern 24 will be between 2 mm and 6 mm. It can also be seen in various embodiments that the lateral span 58 of the unembossed / flat area 26 is generally greater than the lateral span 56 of the elongated embossed pattern 24. In other words, the unembossed / flat area 26 is preferably wider than the elongated embossed pattern 24.

[0176] A wider unembossed / flat region 26 compared to the elongated embossing 24 offers the advantages of maintaining most of the filtration properties of the original filter media sheet 12 (e.g., reducing the need for stretching / compression in the unembossed / flat region 26), and the flat region allows for easier formation and stretching of the embossing 24. The wider unembossed / flat region 26 also provides larger volume inlet and outlet flow channels 28, 29. Therefore, preferably, the lateral span of the unembossed / flat region 26 is at least 200%, more preferably between 200% and 600%, and most preferably between 225% and 325% of the lateral span 56 of each elongated embossing 24.

[0177] For the first three groups of the illustrated implementation scheme, and especially for Figure 1-24 Another common feature of the filter media packages 10, 110, and 210 is that all the elongated embossing 24 in the pleated filter media packages 10, 110, and 210 face the same direction. This is achieved by the pleated filter media packages 10, 110, and 210 having successively alternating first panels 20A and second panels 20B, wherein the elongated embossing 24 on the first panel 20A protrudes outward from the first side 60 of the filter media sheet 12, and the elongated embossing 24 on the second panel 20B protrudes outward from the second side 62 of the filter media sheet 12 opposite to the first side 60.

[0178] On the contrary, such as Figure 25-31 As shown in the angled alignment embodiment of the filter media package 310, the elongated embossing 24 faces opposite directions instead of the same direction (e.g., half of the embossing 24 faces one direction and the other half faces the other direction).

[0179] Now we turn to the various implementation schemes in more detail. Figure 1-15 An elongated embossing 24 with a saddle 30 is shown. The saddle 30 is shown to provide a variable height embossing profile including alternating peaks 70 and valleys 72. These saddles 30 can provide a variety of potential advantages, including any one or more of the following: enhancing the structural rigidity of the embossing and filter media sheet, reducing clogging between pleated panels, or preventing / reducing slackness of the media perpendicular to the embossing direction.

[0180] like Figure 5 and 12 As shown in -14, these peaks 70 and valleys 72 can follow a sinusoidal path with a repetition period 74. The period 74 of the sinusoidal path has an offset 74 between adjacent elongated embossings 24A, 24B, such that the peak 70 of the first elongated embossing 24A laterally coincides with the valley 72 of the second elongated embossing 24B adjacent to the first elongated embossing 24A.

[0181] like Figure 5 and 12 As shown in -14, the period 74 can be offset between 1 / 4 and 3 / 4. For example, in Figure 13 There exists a 1 / 4 offset of 76 from period 74; and in Figure 13 and 14 There exists a 1 / 2 offset of period 74, 76.

[0182] Figure 14 Also relative to Figure 12 The period 76 is shown to be longer or shorter. For example, a saddle is periodically placed every 2 to 8 centimeters to promote enhanced anti-clogging effect while maintaining rigidity.

[0183] Alternatively, such as Figure 15 As shown, saddle 30 follows a repetitive period of 78 in a non-sinusoidal path. Figure 15 In one embodiment, the peak takes the form of an elongated ridge 80 extending between adjacent saddles 30. In this design, preferably, the longitudinal span 82 of the elongated ridge 80 is at least 50% of the longitudinal span 84 of the saddle, and preferably between 50% and 300% of the longitudinal span 84 of the saddle.

[0184] and Figure 12-14 The situation is the same and similar, in Figure 15 In the process, the period 78 of the non-sinusoidal path can be found in adjacent slender embossings ( Figure 15 The offset between the two (not shown) causes the peaks of the first elongated embossing to laterally coincide with the valleys of the second elongated embossing adjacent to the first elongated embossing. This increases rigidity because potential pivot points that could arise from the saddle area do not coincide but are offset, thus providing rigidity to the pleated panel.

[0185] It should be understood that Figure 12-15 Any saddle profile used can be used Figure 1 and 2 The filter media package 10 and sheet 12 are in the filter media packaging.

[0186] Turning Figure 8-11 Any saddle can be constructed as follows: Figure 8 As shown, it is compressed, as Figure 9 As shown, it is being cut, or as Figure 10-11The image shows a translation. For example, as shown... Figure 8 and 9 As shown, the base of the saddle 30 may have the same lateral width as the peak 70; or it may have a width similar to that of the peak 70. Figure 10-11 The narrower translation width is shown. Any of these contours can be used... Figure 12-15 Any outline implementation scheme in the outline implementation scheme.

[0187] like Figure 8 As shown, the embossed profile is compressed, causing a change in height while the base width remains constant. Alternatively, in... Figure 9 In this process, the embossing profile is cut from the top of the peak, maintaining the base dimensions of the original embossing profile. As an alternative, the embossing profile can be as follows: Figure 10-11 The translation shown involves shifting the embossed outline downwards, thereby changing the base width.

[0188] In various embodiments, the saddle provides a valley 72 between adjacent peaks 70. The elongated embossing 24 may have a minimum depth 86 at the valley 72, which is between 25% and 75% of the maximum depth 88 at the peak 70 (more preferably, the minimum depth 86 is between 35% and 65% of the maximum depth 88). The maximum depth 88 is considered to be the same as the embossing depth 54. Note, for example, as... Figure 8 As shown, when measuring a minimum depth of 86, this measurement should be taken at the apex (e.g., at a depth of 86). Figure 8 (At the center of the symmetrical end profile shown). Furthermore, assuming the filter media sheet thickness remains constant (i.e., uncompressed / unexpanded), depths 86, 88 (e.g., 54) can be measured from the top surface of the sheet (to measure the embossing height to the top of the embossing) or from the bottom surface of the sheet 12 (to the bottom of the embossing groove), as... Figure 4 As shown, these same measurements are performed because of the thickness of sheet 12.

[0189] like Figure 10-11 As shown, optionally, the embossing 24 can vary in the lateral width span 56, wherein the minimum lateral width span is defined at the valley and the maximum lateral width span is defined at the peak. The minimum lateral width span 90 is between 50% and 100% of the maximum lateral width span 92 (e.g., typically the same as the embossing lateral span 56), and if the lateral width varies, the minimum lateral width span is more preferably between 60% and 85% of the maximum lateral width span. Figure 10 , 11 As shown, the lateral span 92 can be measured along the base (surface) of the sheet, from which the embossing protrudes upwards.

[0190] Next reference Figure 16 , 18The offset alignment embodiment of 19 shows an offset alignment 32 for the elongated embossing 24. Offset alignment 32 increases the structural stiffness of the filter media package 110 by shortening the "beam" along the unembossed / flat area 26, preventing package collapse under high pressure differentials. This offset alignment 32 moves the embossed contact point to a geometrically stronger location. This can be compared... Figure 16 and 17 To see it at the best time, among them Figure 17 The off-alignment feature that is not available for comparison is shown.

[0191] Figure 17 It shows in Figure 1-15 The highly effective implementation of the change and Figure 20-24 The typical symmetrical elongated embossing offset used in the bridging embossing implementation is as follows: In a typical symmetrical elongated embossing offset, the elongated embossing 24 on the first panel 20A is arranged to contact at the midpoint between the elongated embossing 24 on the second panel 20B (e.g., along an unembossed flat area or bridging embossing contained therein); and the elongated embossing 24 on the second panel 20B is arranged to contact at the midpoint between the elongated embossing 24 on the first panel 20A (e.g., along an unembossed flat area or bridging embossing contained therein).

[0192] For comparison Figure 16 and 17 As shown, in Figure 16 In the asymmetric configuration (shifting the contact from the midpoint between embossed 24), the effective fulcrum moves away from the midpoint of the unembossed / flat area 26. This can provide a smaller deflection, such as Figure 16 and 17 The idealized / represented flexural deformation of the filter media sheet, shown by dashed lines, is illustrated (assuming a similar load / force is applied). Specifically, with... Figure 17 In contrast, through slender embossing closer to adjacent pleated panels, in such Figure 16 The unembossed / flat area 26 shown has a lower chance of bending.

[0193] As shown in the figure Figure 16 , 18 19 achieves an offset alignment 32 of a first set of elongated embossing 24C of a first panel 20A and a second set of elongated embossing 24D of a second panel 20B, the second set of elongated embossing 24D protruding in the same direction as the first set (e.g., on different adjacent pleated panels that may be repeated). The first set of elongated embossing 24C engages with corresponding areas of the unembossed / flat region 26 of the second panel 20B at a position offset from the lateral midpoint 96, which is defined between corresponding adjacent embossings 24D of the corresponding area of ​​the unembossed / flat region 26 of the second panel 20B.

[0194] Similarly, the second set of elongated embossings 24D joins the corresponding area of ​​the unembossed / flat area 26 of the first panel 20A at a position offset from the lateral midpoint 96, which is defined between the corresponding adjacent embossings 24C of the corresponding area of ​​the unembossed / flat area 26 of the first panel 20A.

[0195] The unembossed / flat area 26 extends laterally across a span 58 between adjacent elongated embossings 24 on each panel, with a lateral midpoint 96 located in the middle and at 50% of the lateral span 58 of the unembossed / flat area 26 (e.g., along a position perpendicular to the longitudinal direction of the elongated embossings). To maximize the aforementioned benefits, the first set of elongated embossings 24C is joined at a position between 0% and 30% of the lateral span 58 (i.e., at least 20% away from the midpoint), and more preferably at a position between 5% and 20% of the lateral span 58 of the unembossed / flat area 26.

[0196] This is particularly useful in the case of a larger lateral span of the unembossed / flat region 26, where most of the filter media may not be structurally formed / reinforced, and thus essentially retain the original filtration properties of the filter media sheet 12. Furthermore, wider flow channels can be achieved. For example, the span of the unembossed / flat region is at least 200% of the maximum width, wherein the lateral span of the unembossed / flat region is preferably between 200% and 600% of the maximum width of the elongated embossing.

[0197] Next turn Figure 20-24 The bridging embossing implementation will discuss additional details of the bridging embossing 34. The bridging embossing 34 increases structural stiffness in a direction different from the longitudinal direction of the elongated embossing 24. The bridging embossing 34 adds structure to the unembossed / flat area 26 between the embossings 24, supporting the filter media package 210 to prevent collapse under high differential air pressure during use. The bridging embossing 34 also reduces clogging and similarly provides more intermittent contact points between the embossed tip and the flat portion, but in a different manner than with variable height embossing.

[0198] Typically, the bridging embossing 34 extends laterally between adjacent members of the elongated embossings 24A, 24B by more than 50% of the lateral span (e.g., the lateral span 58 of the unembossed flat area), and preferably extends between 70% and 110% of the lateral span 58 (when the bridging embossing 34 is incorporated into the area of ​​the elongated embossing 24, the bridging embossing can extend slightly beyond the span, as shown). Most preferably, the bridging embossing completely spans the unembossed / flat area, connecting adjacent members of the elongated embossing to maximize structural stiffness and avoid bending areas of the filter media sheet between the embossings.

[0199] like Figure 20-24As shown, preferably, all unembossed / flat areas 26 have bridging embossing 34 formed therein. However, not all unembossed / flat areas 26 need to have such bridging embossing 34 formed therein, and benefits can be achieved if some embossed / flat areas 26 have bridging embossing.

[0200] Typically, at least 75% and preferably 90%-100% of the unembossed / flat area is between adjacent elongated embossed components.

[0201] Furthermore, preferably, all panels 20 with elongated embossing (e.g., adjacent panels 20A, 20B) have this bridging embossing 34, but the same benefit can be achieved even if alternating panels have this bridging embossing 34.

[0202] The bridging embossing 34 can project in the same direction as the embossing on each panel and still provide the benefit of rigidity, but more preferably it can project in the opposite direction along each panel 20 to enhance intermittent contact, such as Figure 20-24 As shown. The bridging embossing 34 and the elongated embossing 24 protrude outward from opposite sides 60 and 62 of the filter medium sheet 12, respectively.

[0203] Furthermore, in order to align the elongated embossing 24 in the common direction when folded into the filter media package 210, such as Figure 21 As shown, the bridging embossing 34 protrudes from one side on some panels 20A, and the bridging embossing 34 also protrudes from the other side on other panels 20B. This is in Figure 23A As better illustrated in the diagram. Thus, the bridging embossing 34 can protrude in opposite directions when formed into the filter media sheet (e.g., in a filter media sheet that is located on a flat surface after formation, some of the bridging embossing 34 protrudes upward on the top surface 60 of the filter media sheet 12, and some of the bridging embossing 34 protrudes downward below the bottom surface 62 of the filter media sheet 12).

[0204] In particular, such as Figure 21 and Figure 24 As shown, all the elongated embossed patterns 24 in the pleated filter media package 210 face the same direction, wherein the pleated filter media package 24 has a continuously alternating first panel 20A and second panel 20B. See also... Figure 23AA magnified view shows that the elongated embossing 24 on the first panel 20A protrudes outward from the first side 60 of the filter medium sheet 12 (e.g., the top sheet surface during forming via a roller or flat die), and the elongated embossing 24 on the second panel 20B protrudes outward from the second side 62 of the filter medium sheet 12 opposite to the first side (e.g., the bottom sheet surface during forming via a roller or flat die). Bridging embossing 34 protrudes outward from the elongated embossing in opposite directions on each panel 20. Specifically, the bridging embossing 34 on the first panel 20A protrudes outward from the second side 62 of the filter medium sheet 12 (e.g., from the bottom sheet surface during forming via a roller or flat die), and the bridging embossing 34 on the second panel 20B protrudes outward from the first side 60 of the filter medium sheet 12 (e.g., from the top sheet surface during forming via a roller or flat die).

[0205] In addition to providing bridging strength, the bridging embossing 34 can be used to achieve intermittent contact and enhance the elongated embossing 24. In the assembled pleated filter media package 210, and as... Figure 21 The best is shown in the middle (see also) Figure 22 The elongated embossing 24 on the first panel 20A contacts the bridging embossing 34 of the second panel 20B adjacent to the first panel 20A. This can lift most of the ridges of the elongated embossing 24 away from the unembossed / flat area 26 of the filter media sheet 12.

[0206] The bridging embossing 34 is also relatively shallow so as not to obstruct airflow in the inlet flow channel 28 and the outlet flow channel 29. The bridging embossing 34 can also be less wide to maximize the unformed remaining area of ​​the unembossed / flat area 26. For example, the bridging embossing defines a bridging width 98 and a bridging depth 100 (the same measurement as the bridging height), as... Figure 21 and 22 As shown, (a) the bridging width 98 may be between 10% and 50% of the maximum width of the elongated embossing 24 (i.e., the lateral span of the embossing 56), and more preferably between 20% and 40% of the maximum width of the elongated embossing 24; and the bridging depth is between 10% and 50% of the maximum depth of the elongated embossing, and more preferably between 20% and 40% of the maximum depth of the elongated embossing.

[0207] For example, the bridging width 98 can be between 1 mm and 3 mm, more preferably between 1 mm and 2 mm. The bridging length 104 is preferably the same as or closely matched with the length of the lateral span 58 of the unembossed / flat area (usually minimum / slightly larger, as the bridging piece can enter the span of the elongated embossing or rise onto the slope of the elongated embossing 24, such as...). Figure 20 and 21As shown), the bridging embossing completely spans between adjacent elongated embossings. For example, the lateral span 58 and bridging length 104 can typically be between 4 mm and 36 mm, and more preferably between 8 mm and 20 mm. Furthermore, for example, the maximum bridging embossing depth can be between 0.2 mm and 1.0 mm, and more preferably between 0.3 mm and 0.8 mm.

[0208] In the preceding paragraphs, the bridging length 104 of the bridging embossing 34 is measured perpendicular to the elongated embossing 20, as shown in the figure, whereby the bridging embossing 34 extends perpendicular to the elongated embossing 20. It is conceivable that the bridging embossing could alternatively extend at an angle relative to the elongated embossing 20, in which case the actual bridging length, if spanning the entire distance between the elongated embossings 24, would be substantially greater than the lateral span 58 of the unembossed / flat area. Therefore, in some embodiments with angled bridging embossings instead of the bridging length 104, bridging span might be a better term used to describe the bridging span contemplated, which measures the span of embossings that are vertically bridging each other, regardless of whether the bridging embossing extends vertically or at an angle (e.g., the bridging embossing span is preferably the same as or closely matched to the span 58 of the lateral span of the unembossed / flat area). Therefore, the term bridging length / span can be used to cover bridging embossing that extends vertically or diagonally, and the measurement is the vertical span between the slender embossings (thus indicating the extent to which the lateral span between the slender embossings is covered).

[0209] Another feature shown is that a pair of formed gusset plates 102 integrally connect the bridging embossing 36 and the slender embossing 24 at their intersection, thereby enhancing the structural support / rigidity and providing a smooth transition and merging therebetween.

[0210] Next, turn to Figure 25-31 This embodiment of the filter media packaging 310 has embossing reinforcement as an angled alignment 36 of an elongated embossing 24, wherein the elongated embossing 24 extends at an oblique angle relative to the pleats 14. Figures 28-29 As best illustrated, this provides intermittent contact points between the unembossed / flat area 26 and the raised embossed area 24. For example, these contact points prevent nesting of the embossing while reducing media blockage. Furthermore, there may be speculative effects from the turbulent airflow generated by the alternating flow paths, thus creating a "clearing" effect within the media package.

[0211] The angled, elongated embossing 24 does not extend through the pleat 14, but stops before reaching the pleat 14 due to the provided crease area 46.

[0212] Angled embossing can also more easily facilitate continuous embossing processes, such as using mating rollers, and can form scribe lines and crease areas 46 for folding after embossing. Separating embossing and scribes will allow for customized fold heights without significant tooling costs. Additionally, if continuous embossing is produced in the sheet 12 using rollers, a second / auxiliary step can be achieved to flatten a portion and periodically scribe it into the crease area 46 (thus eliminating small segments of continuous embossing).

[0213] Considering the need to maintain axial flow in the filter media package 310 between the inlet flow surface 16 and the outlet flow surface 18, the angle of the elongated embossing should generally be less than 45 degrees. For example, according to the angled alignment 36, the elongated embossing protrudes at an angle 106 between 2 and 10 degrees relative to the pleats, and more preferably between 3 and 8 degrees, most preferably about 5 degrees.

[0214] Preferably, the elongated embossing 24 extends linearly according to the angled alignment 36, but the angled alignment 36 also encompasses a curved profile, wherein the tangent of the curvature may be inclined relative to the fold 14.

[0215] Furthermore, the slender embossed patterns 24 are formed in the filter media sheet in a common inclined direction, such as... Figure 31 As shown in the optimal diagram, where the folded arrangement (see...) Figures 28-29 In (30), the elongated embossings 24E and 24F on adjacent panels 20A and 20B are angled in opposite tilting directions, as shown therein. For example, embossing 24E extends in one tilting direction on the first panel 20A, and embossing 24F on the second panel 20B extends in the other direction and is pressed into the filter media package 310 once folded.

[0216] For example, such as Figure 31 As shown, at least one (and preferably all) of elongated embossings 24 having angled alignment 36 can be formed parallel to each other in the filter medium sheet 12, such that the elongated embossings 24 on adjacent panels are angled in opposite directions.

[0217] As shown in the figure and as is obvious to a person of ordinary skill, apart from the outermost panel of the filter media package, the first panel 20A is adjacent to two second panels 20B, and thus sandwiched between a pair of adjacent second panels 20B. Similarly, the second panels 20B are adjacent to two first panels 20A, and thus sandwiched between a pair of adjacent first panels 20A.

[0218] One way to provide intermittent contact positions with the elongated embossing 24 at an angle 35 is to provide a first array 130 of elongated embossing 24 projecting outward from a first side 60 (e.g., the top surface of the filter media sheet 12), and a second array 132 of elongated embossing 24 projecting outward from a second side 62 opposite to the first side 60 (e.g., the bottom surface of the filter media sheet 12). Through this configuration of opposing protruding embossing arrays 130, 132 and employing embossing 24 (e.g., at least one set or all) angled in a common direction as formed in the filter media sheet 12, (when assembled into the filter media package 310 via pleats 14) the elongated embossing 24 on alternating adjacent panels 20A, 20B are angled relative to each other in opposite directions, such as... Figures 28-30 As shown.

[0219] This feature of the opposing, protruding embossed arrays 130, 132 is particularly useful when used alone to produce the intermittent contact points shown in the filter media package 310. Furthermore, additional features, such as a combination of at least one saddle 30 and bridging embossing 34, can be used in the filter media package 310. The filter media package 310 has opposing, protruding embossed arrays 130, 132.

[0220] In the absence of opposing protruding embossed arrays 130, 132, the offset alignment 32 feature can be more easily combined. For example, although not shown, when formed in the angled alignment 36, the elongated embossing 24 can be formed to protrude only from either of the sides 60, 62 (e.g., the top or bottom surface during the stamping of the filter media sheet 12 with a roller or plate press), which can be combined with other features (e.g., bridging embossing 34 to provide intermittent contact and offset alignment 32). Additionally, the saddle 30 is used in conjunction with the angled alignment to create intermittent contact positions.

[0221] Additional embodiments with combinations of embossed reinforcement features are shown in filter media packages 410 and 510, wherein the features used are the same as those used in the previous filter media packages 10, 110, and 210, only according to different combinations as shown in Table 1 above. Therefore, the discussion of these features will be limited to combinations of these features that have been previously disclosed and discussed in detail.

[0222] For example, in the filter media package 410 of Figures 35-36, the filter media sheet 12 is formed with a combination of a saddle 30 (variable embossing height) and an offset alignment 32 feature. Regarding Figure 1-15 The advantages and discussion of the construction of the saddle 30 (variable embossing height) feature described also apply to this embodiment; and similarly, regarding Figure 16-19The advantages and discussion of the construction of the offset alignment 32 feature described also apply to this embodiment. The combination of the saddle 30 and the offset alignment 32 can also work together to provide structural rigidity and intermittent contact in multiple directions simultaneously.

[0223] As another example, in Figures 37-38 In the filter media package 510, the filter media sheet 12 is formed with a combination of a saddle 30 (variable embossing height), offset alignment 32, and bridging embossing 34. Regarding Figure 1-15 The advantages and discussion of the construction of the saddle 30 (variable embossing height) feature described also apply to this embodiment; and similarly, regarding Figure 16-19 The advantages and discussion of the construction of the offset alignment 32 feature described also apply to this implementation; and similarly, regarding Figure 20-24 The advantages and discussion of the construction of the bridging embossing 34 described also apply to this embodiment. The combination of the saddle 30, the offset alignment 32, and the bridging embossing 34 can also work together to provide structural rigidity and intermittent contact in multiple directions simultaneously.

[0224] Additional observations / implementation plan Unless otherwise expressly stated, the additional / implementations discussed below are intended to be covered by the appended claims.

[0225] In various filter media packages 10, 110, 210, 310, 410, and 510, the inlet flow surface 16 has a flat configuration, and the outlet flow surface 18 has a flat configuration, and preferably, the inlet flow surface 16 and the outlet flow surface 18 are coplanar. However, in some embodiments of the invention, other possibilities of non-planar or non-coplanar configurations may be implemented.

[0226] Additionally, embossing 24 and features 30, 32, 34, and 36 are shown on each pleated panel 20, which is the easiest from a handling and benefit perspective. However, not all pleated panels 20 need to include embossing 24. Not all pleated panels 20 need to include one or more of features 30, 32, 34, and 36. It should be understood that unless stated as “all” panels, less than all panels may include embossing 24 and one or more of features 30, 32, 34, and 36. For maximum advantage, generally virtually all (i.e., at least 80%) of the pleated filter media packages have elongated embossing formed therein. Sometimes, the outermost panels may not require such embossing or embossing reinforcement because they can be mounted to a sealing system and / or mounting frame used with the filter cartridge.

[0227] Additionally, in some implementations, embossing 24 and features 30, 32, 34, 36 may be on alternating panels, which may be the case if a flat panel is used on the first panel and embossing is used on the second panel.

[0228] Filter media packages are useful in air filter cartridges comprising one of pleated filter media packages 10, 110, 210, 310, 410, and 510. For example, pleated filter media packages 10, 110, 210, 310, 410, and 510 can be used in air filters and with a sealing system or mounting frame as shown in U.S. Patent Publication US20220126227A1, entitled “Gasket And Frame Assembly For Air Filter” by Krull et al., which is incorporated herein by reference, because any filter media package disclosed therein can be superseded by U.S. Patent Publication US20220126227A1 by Krull et al. As will be understood with reference thereto, a filter cartridge may be provided comprising a housing seal mounted to the pleated filter media package 10, 110, 210, 310, 410, and 510, and optionally a sealing support for mounting the housing seal.

[0229] Furthermore, while the above embodiments are described as having significant advantages for pleated filter media packages 10, 110, 210, 310, 410, and 510, it should be understood that the various embossing enhancement features disclosed herein (saddle 30, offset alignment 32, bridging embossing 34, and angled alignment 36) can be used with other types of media packages besides pleated media packages, such as stacked slotted media panels and slotted filter media packages, as disclosed and described in Merritt’s U.S. Publication No. 2014 / 0260139 entitled “Rectangular Stacked Fluted Fluter Cartridge,” the entire contents of which are incorporated herein by reference (see, for example, its...). Figure 26 (This refers to a design with stacked, slotted media panels sealed with end adhesive beads). The advantages of the various embossed reinforcement features described herein are not necessary in such designs, as structural integrity is provided by the adhesive end-sealing beads (and possibly sticky beads) that provide self-supporting blocks. Furthermore, this alternative embodiment of the invention is not preferred because the end-sealing beads offer the possibility of leakage paths in the individual grooves between the cutting blades and also reduce filtration capacity. However, and therefore certain broader claims appended (e.g., claims that do not explicitly claim pleats or corrugations) are intended to cover this possibility of such stacked slotted media panels and slotted filter media packages, as some benefits can be achieved in this alternative embodiment.

[0230] All references cited in this article (including publications, patent applications and patents) are incorporated herein by reference to the extent that each reference is individually and specifically indicated as incorporated by reference and described in full in this article.

[0231] In the context of describing the invention (particularly in the context of the following claims), the terms “a,” “an,” and “the,” and similar indicators, should be interpreted as encompassing both singular and plural, unless otherwise stated herein or obviously contradicted by the context. Unless otherwise stated, the terms “comprising,” “having,” “including,” and “containing” should be interpreted as open-ended terms (i.e., meaning “including but not limited to”). Unless otherwise stated herein, the description of value ranges herein is intended only as a shorthand method of individually referring to each individual value falling within that range, and each individual value is incorporated into the specification as if it were individually described herein. All methods described herein may be performed in any suitable order, unless otherwise stated herein or obviously contradicted by the context. Unless otherwise stated, the use of any and all examples or exemplary language (e.g., “such as”) provided herein is intended only to better illustrate the invention and does not constitute a limitation on the scope of the invention. The language in the specification should not be construed as indicating that any unclaimed element is essential for the practice of the invention.

[0232] This document describes preferred embodiments of the invention, including the best modes known to the inventors for carrying out the invention. Variations of those preferred embodiments will become apparent to those skilled in the art upon reading the foregoing description. The inventors expect those skilled in the art to appropriately employ such variations, and the inventors intend to practice the invention in ways different from those specifically described herein. Therefore, the invention includes all modifications and equivalents of the subject matter recited in the appended claims as permitted by applicable law. Furthermore, unless otherwise stated herein or clearly contradicted by the context, the invention covers any combination of the foregoing elements in all possible variations.

Claims

1. A pleated filter media package, comprising: A filter medium sheet folded along the folds at the inlet flow surface and the folds at the outlet flow surface to provide a plurality of folds having a panel extending between the inlet flow surface and the outlet flow surface; Multiple elongated embossed patterns are formed in the filter media sheet and extend longitudinally between the inlet flow surface and the outlet flow surface. The elongated embossed patterns are laterally spaced and separated by unembossed / flat areas. as well as Provide at least one of the following features: (a) A saddle formed in the elongated embossing that is elevated relative to the unembossed / flat area; or (b) Offset alignment of elongated embossing, including a first group of elongated embossing on a first panel and a second group of elongated embossing on a second panel, the elongated embossing of the second group protruding in a direction common to the first group, wherein the elongated embossing of the first group engages a corresponding area of ​​an unembossed / flat area of ​​the second panel at a position offset from the lateral midpoint, the lateral midpoint being defined between corresponding adjacent embossings of the corresponding areas of the unembossed / flat area of ​​the second panel; or (c) A bridging embossing formed in the unembossed / flat area, the bridging embossing extending laterally between adjacent members of the elongated embossing; or (d) Angle alignment of elongated embossings, wherein the elongated embossings extend at an angle relative to the folds and have intermittent contact positions.

2. The pleated filter media packaging according to claim 1, wherein the elongated embossing extends between 75% and 99% of the span of the panel between the inlet flow surface and the outlet flow surface, and more preferably between 95% and 99% of the span of the panel between the inlet flow surface and the outlet flow surface.

3. The pleated filter media packaging according to claim 1, wherein the crease regions extend laterally between opposite edges of the filter media sheet, and wherein the crease regions have a width parallel to the opposite edges, the width spanning between 0.1 cm and 3.0 cm, more preferably between 0.2 cm and 1.0 cm, and wherein at least one crisscross is formed in each crease region to facilitate the pleats, and wherein the elongated embossing is located outside the crease regions and tapers toward the crease regions at the opposite ends of the elongated embossing.

4. The pleated filter media packaging according to claim 3, wherein, All of the elongated embossings extend continuously across the entire span between the crease areas at opposite ends of the elongated embossings.

5. The pleated filter media packaging according to claim 1, wherein the panel extends between a span of 7 cm and 45 cm, more preferably between 10 cm and 35 cm, between the inlet flow surface and the outlet flow surface.

6. The pleated filter media packaging according to claim 1, wherein the filter media sheet comprises cellulose fiber, synthetic polymer fiber or glass fiber.

7. The pleated filter media packaging according to claim 6, wherein the filter media sheet comprises a blend of fibers, the blend of fibers comprising cellulose fibers and synthetic polymer fibers, wherein the blend of fibers comprises more than 50% cellulose fibers by weight; and more preferably between 70%-90% cellulose fibers and 10%-30% synthetic polymer fibers; and most preferably between 75%-85% cellulose fibers and 15%-25% synthetic polymer fibers.

8. The pleated filter media packaging according to claim 1, wherein, No adhesive is applied between the panels of the filter media sheet inside the pleated filter media package.

9. The pleated filter media packaging according to claim 1, wherein, The maximum depth of the slender embossing is between 1.0 mm and 4.5 mm, more preferably between 1.0 mm and 2.0 mm, and most preferably between 1.3 mm and 1.6 mm.

10. The pleated filter media packaging according to claim 1, wherein the lateral span of the unembossed / flat area within the inner region of the pleated filter media packaging is at least 200% of the lateral span of each of the elongated embossings, more preferably between 200% and 600%, and most preferably between 225% and 325%.

11. The pleated filter media packaging according to claim 1, wherein, All the elongated embossings in the pleated filter media package face the same direction, the pleated filter media package having a continuous alternating first panel and a second panel, wherein the elongated embossings on the first panel protrude outward from a first side of the filter media sheet, and the elongated embossings on the second panel protrude outward from a second side of the filter media sheet opposite to the first side.

12. The pleated filter media packaging according to claim 1, wherein, The at least one feature provides both lateral bridging strength between embossed patterns and intermittent contact points.

13. The pleated filter media packaging according to claim 1, wherein, The at least one feature includes at least two features selected from the group consisting of (a) saddle, (b) offset alignment, and (c) bridging embossing.

14. The pleated filter media packaging according to claim 13, wherein, The at least one feature includes all of the following: (a) saddle, (b) offset alignment, and (c) bridging embossing.

15. The pleated filter media packaging of claim 1, wherein at least one feature comprises an angled alignment of elongated embossings, wherein a first array of elongated embossings protrudes outward from a first side of the filter media sheet, and a second array of elongated embossings protrudes outward from a second side of the filter media sheet opposite to the first side.

16. The pleated filter media packaging according to claim 1, wherein, The at least one feature includes at least a saddle, and wherein the elongated embossing includes a variable embossing profile, the variable embossing profile including alternating peaks and valleys following a sinusoidal path with a repeating period, and wherein the period of the sinusoidal path is offset between adjacent elongated embossings such that the peaks of the first elongated embossing laterally coincide with the valleys of the second elongated embossing, the second elongated embossing being adjacent to the first elongated embossing.

17. The pleated filter media packaging of claim 16, wherein the period is offset from 1 / 4 to 3 / 4 of the period, and more preferably from 1 / 2 of the period.

18. The pleated filter media packaging according to claim 1, wherein, The at least one feature includes at least a saddle, and wherein the saddle follows a repetitive period in a non-sinusoidal path.

19. The pleated filter media packaging according to claim 18, wherein, The elongated ridges are located between adjacent saddles, and the longitudinal span of the elongated ridges is at least 50% of the longitudinal span of the saddles, preferably between 50% and 300% of the longitudinal span of the saddles.

20. The pleated filter media packaging according to claim 18, wherein, The period of the non-sinusoidal path is offset between adjacent slender embossings, such that the peak of the first slender embossing coincides laterally with the valley of the second slender embossing, and the second slender embossing is adjacent to the first slender embossing.

21. The pleated filter media packaging according to claim 1, wherein, The at least one feature includes at least a saddle that provides a valley between adjacent peaks, wherein the elongated embossing has a minimum depth at the valley between 25% and 75% of the maximum depth at the peak, and more preferably, the minimum depth is between 35% and 65% of the maximum depth.

22. The pleated filter media packaging of claim 1, wherein the at least one feature comprises at least a saddle providing a valley between adjacent peaks, and wherein the lateral width span of the elongated embossing is optionally varied, wherein a minimum lateral width span is defined at the valley and a maximum lateral width span is defined at the peak, wherein the minimum lateral width span is between 50% and 100% of the maximum lateral width span, and if the lateral variation is present, the minimum lateral width span is more preferably between 60% and 85% of the maximum lateral width span.

23. The pleated filter media packaging according to claim 1, wherein, The at least one feature includes at least a saddle, wherein a saddle is periodically provided every 2 to 8 centimeters.

24. The pleated filter media packaging of claim 1, wherein the at least one feature includes at least offset alignment, wherein the unembossed / flat area extends a lateral span between adjacent elongated embossings on each panel, wherein the lateral midpoint between the adjacent elongated embossings is thereby located at 50% of the lateral span, wherein the elongated embossings of the first group engage at a position between 0% and 30% of the lateral span, and more preferably at a position between 5% and 20% of the lateral span.

25. The pleated filter media packaging according to claim 24, wherein, The lateral span of the unembossed / flat area is at least 200% of the maximum width of the elongated embossing, and the lateral span of the unembossed / flat area is preferably between 200% and 600% of the maximum width of the elongated embossing.

26. The pleated filter media packaging of claim 1, wherein the at least one feature comprises at least bridging embossing, and wherein the bridging embossing extends laterally greater than 50% of the lateral span between adjacent members of the elongated embossing, and preferably between 70% and 110% of the lateral span.

27. The pleated filter media packaging of claim 26, wherein the bridging embossing completely spans the unembossed / flat area, connecting adjacent members of the elongated embossing.

28. The pleated filter media packaging according to claim 1, wherein, The at least one feature includes bridging embossing, wherein at least 75% and preferably 90%-100% of the unembossed / flat areas have bridging embossing between adjacent members of the elongated embossing on all panels having the elongated embossing.

29. The pleated filter media packaging of claim 1, wherein the at least one feature comprises at least bridging embossing, wherein on each panel, the bridging embossing and the elongated embossing project outward from opposite sides of the filter media sheet, respectively.

30. The pleated filter media packaging according to claim 1, wherein, In the pleated filter media package, all the elongated embossed surfaces face the same direction, and the pleated filter media package has continuously alternating first and second panels, wherein: (a) The elongated embossing on the first panel protrudes outward from a first side of the filter media sheet, and the elongated embossing on the second panel protrudes outward from a second side of the filter media sheet opposite to the first side; and (b) The bridging embossing on the first panel protrudes outward from the second side of the filter media sheet, and the bridging embossing on the second panel protrudes outward from the first side of the filter media sheet opposite to the second side.

31. The pleated filter media packaging of claim 1, wherein the at least one feature comprises at least bridging embossing, and wherein the elongated embossing on the first panel contacts the bridging embossing of a second panel adjacent to the first panel.

32. The pleated filter media packaging of claim 1, wherein the at least one feature comprises at least bridging embossing, wherein the bridging embossing defines a bridging width and a bridging depth, and wherein: (a) The bridging width is between 10% and 50% of the maximum width of the slender embossing, and more preferably between 20% and 40% of the maximum width of the slender embossing; as well as (b) The bridging depth is between 10% and 50% of the maximum depth of the elongated embossing, and more preferably between 20% and 40% of the maximum depth of the elongated embossing.

33. The pleated filter media packaging according to claim 1, wherein, The at least one feature includes at least a bridging embossing, and also includes a pair of formed gusset plates integrally connecting the bridging embossing to the elongated embossing.

34. The pleated filter media packaging according to claim 1, wherein, The at least one feature includes at least a bridging embossing, wherein the bridging embossing is an elongated bridging embossing, the elongated bridging embossing defining a bridging length / span between adjacent members of the elongated embossing and a bridging width perpendicular thereto, wherein the bridging width is between 1 mm and 3 mm, more preferably between 1 mm and 2 mm; and wherein the bridging length / span is between 4 mm and 36 mm, more preferably between 8 mm and 20 mm; and wherein the maximum bridging embossing depth is between 0.2 mm and 1.0 mm, more preferably between 0.3 mm and 0.8 mm.

35. The pleated filter media packaging according to claim 1, wherein, The at least one feature includes at least bridging embossing, and wherein all panels including elongated embossing also include the bridging embossing.

36. The pleated filter media packaging according to claim 1, wherein, The at least one feature includes at least an angled alignment of an elongated embossed pattern, wherein the elongated embossed pattern protrudes at an angle between 2 and 10 degrees relative to the pleated portion, and more preferably at an angle between 3 and 8 degrees, and most preferably at an angle of about 5 degrees.

37. The pleated filter media packaging according to claim 1, wherein, The at least one feature includes at least an angled alignment of elongated embossing, wherein the elongated embossing extends linearly.

38. The pleated filter media packaging of claim 1, wherein the at least one feature comprises at least angled alignment of elongated embossing, and wherein the elongated embossing is formed in the filter media sheet in a common inclined direction, wherein in the pleated arrangement, the elongated embossing on adjacent panels is angled in opposite inclined directions.

39. The pleated filter media packaging according to claim 38, wherein, At least one set of elongated embossed patterns are formed parallel to each other in the filter media sheet.

40. The pleated filter media packaging according to claim 39, wherein, All the elongated embossed patterns are formed parallel to each other in the filter media sheet.

41. The pleated filter media packaging according to claim 1, wherein, The at least one feature includes angular alignment of elongated embossings, wherein a first array of elongated embossings protrudes outward from a first side of the filter media sheet, and a second array of elongated embossings protrudes outward from a second side of the filter media sheet opposite to the first side, and wherein the embossings are angled along a common direction formed in the filter media sheet, such that, using the folds, the elongated embossings on adjacent panels are angled relative to each other in opposite directions.

42. The pleated filter media packaging according to claim 1, wherein, The at least one feature includes angular alignment of elongated embossings, wherein each of the elongated embossings terminates before reaching the fold, and linear scribings are provided for the fold.

43. The pleated filter media packaging according to claim 42, wherein, Each of the elongated embossed patterns is spaced apart from the pleats and thus stops before reaching the pleats.

44. The pleated filter media packaging according to claim 1, wherein, The inlet flow surface has a flat structure, and the outlet flow surface has a flat structure, and preferably, the inlet flow surface and the outlet flow surface are coplanar.

45. The pleated filter media packaging according to claim 1, wherein, The pleated filter media package has virtually all panels with elongated embossing formed therein.

46. ​​A filter cartridge comprising a pleated filter media package according to claim 1, the filter cartridge comprising a housing seal mounted to the pleated filter media package and a sealing support optionally for mounting the housing seal.

47. A filter media package, comprising: Multiple panels of filter media extending laterally between an inlet flow surface and an outlet flow surface, the multiple panels being arranged generally in parallel, and each panel having a first side and a second side opposite to the first side; Multiple elongated embossed patterns are formed in the panel and extend longitudinally between the inlet flow surface and the outlet flow surface. The elongated embossed patterns are laterally spaced and separated by intermediate regions, each intermediate region being between a corresponding pair of elongated embossed patterns. as well as A saddle, which is formed in an elongated embossed pattern and raised relative to the central region.

48. The filter media packaging according to claim 47, wherein, The plurality of panels are connected in a single continuous sheet folded into a pleated structure, wherein the filter media package is a pleated filter media package.

49. The filter media packaging according to claim 47, wherein, The elongated embossed pattern extends between 75% and 99% of the span of the panel between the inlet flow surface and the outlet flow surface, and more preferably between 95% and 99% of the span of the panel between the inlet flow surface and the outlet flow surface, wherein the panel extends between the inlet flow surface and the outlet flow surface for a span between 7 and 45 cm, more preferably between 10 and 35 cm.

50. The filter media packaging according to claim 47, wherein the filter media sheet comprises a blend of fibers including cellulose fibers and synthetic polymer fibers, wherein the blend of fibers comprises more than 50% cellulose fibers by weight percentage; and more preferably between 70%-90% cellulose fibers and 10%-30% synthetic polymer fibers; and most preferably between 75%-85% cellulose fibers and 15% to 25% synthetic polymer fibers.

51. The filter media packaging according to claim 47, wherein the maximum depth of the elongated embossing is between 1.0 and 4.5 mm, more preferably between 1.0 and 2.0 mm, and most preferably between 1.3 and 1.6 mm.

52. The filter media packaging according to claim 47, wherein within the internal region of the filter media packaging, the lateral span of the intermediate region is at least 200%, more preferably between 200% and 600%, and most preferably between 225% and 325% of the lateral span of each of the elongated embossings.

53. The filter media packaging according to claim 47, wherein, In the filter media package, all the elongated embossed surfaces face the same direction. The filter media package has a continuously alternating first panel and a second panel, wherein the elongated embossing on the first panel protrudes outward from a first side of the filter media sheet, and the elongated embossing on the second panel protrudes outward from a second side of the filter media sheet opposite to the first side.

54. The filter media packaging according to claim 47, wherein, The elongated embossing includes a variable embossing profile comprising alternating peaks and valleys following a sinusoidal path with a repeating period, wherein the period of the sinusoidal path is offset between adjacent elongated embossings such that the peaks of the first elongated embossing laterally coincide with the valleys of the second elongated embossing, the second elongated embossing being adjacent to the first elongated embossing.

55. The filter media package of claim 47, wherein the saddle follows a repetitive cycle in a non-sinusoidal path.

56. The filter media packaging according to claim 55, wherein, The elongated ridges are located between adjacent saddles, and the longitudinal span of the elongated ridges is at least 50% of the longitudinal span of the saddles, preferably between 50% and 300% of the span of the saddles.

57. The filter media packaging according to claim 55, wherein, The period of the non-sinusoidal path is offset between adjacent slender embossings, such that the peak of the first slender embossing coincides laterally with the valley of the second slender embossing, and the second slender embossing is adjacent to the first slender embossing.

58. The filter media packaging of claim 47, wherein the saddle provides a valley between adjacent peaks, wherein the elongated embossing has a minimum depth at the valley between 25% and 75% of the maximum depth at the peak, and more preferably, the minimum depth is between 35% and 65% of the maximum depth.

59. The filter media packaging of claim 47, wherein the saddle provides a valley between adjacent peaks, and wherein the lateral width span of the elongated embossing is optionally varied, wherein a minimum lateral width span is defined at the valley and a maximum lateral width span is defined at the peak, wherein the minimum lateral width span is between 50% and 100% of the maximum lateral width span, and if the lateral variation is present, the minimum lateral width span is more preferably between 60% and 85% of the maximum lateral width span.

60. The filter media packaging according to claim 47, wherein a saddle is periodically provided every 2 to 8 centimeters.

61. The filter media packaging of claim 47, further comprising at least one feature combined with the saddle, said at least one feature being any one or more of the following: (a) offset alignment of embossing away from the midpoint of the intermediate region; (b) bridging embossing formed into the intermediate region; or (c) angled alignment of elongated embossing.

62. The filter media packaging according to claim 47, wherein, The filter media package has virtually all panels with elongated embossing formed therein.

63. A filter media package, comprising: Multiple panels of filter media extending laterally between an inlet flow surface and an outlet flow surface, the multiple panels being arranged generally in parallel, and each panel having a first side and a second side opposite to the first side; Multiple elongated embossed patterns are formed in the panel and extend longitudinally between the inlet flow surface and the outlet flow surface. The elongated embossed patterns are laterally spaced and separated by intermediate regions, each intermediate region being between a corresponding pair of elongated embossed patterns. as well as The offset alignment of the elongated embossing includes a first group of elongated embossings on a first panel and a second group of elongated embossings on a second panel, the second group of elongated embossings on the second panel protruding in the same direction as the first group, wherein the first group of elongated embossings engages a corresponding area of ​​the middle region of the second panel at a position offset from the lateral midpoint, the lateral midpoint being defined between corresponding adjacent embossings in the corresponding area of ​​the middle region of the second panel.

64. The filter media packaging according to claim 63, wherein, The plurality of panels are connected in a single continuous sheet folded into a pleated structure, wherein the filter media package is a pleated filter media package.

65. The filter media packaging according to claim 63, wherein, The filter media package has virtually all panels with elongated embossing formed therein.

66. The filter media packaging according to claim 63, wherein, The second group of slender embossed patterns joins the corresponding area of ​​the middle region of the first panel at a position off-center from the lateral midpoint, the lateral midpoint being defined between corresponding adjacent embossed patterns in the corresponding area of ​​the middle region of the first panel.

67. The filter media packaging of claim 63, wherein the intermediate region extends a lateral span between adjacent elongated embossings on each panel, wherein the lateral midpoint is located at 50% of the lateral span, wherein the elongated embossings of the first group are joined at positions between 0% and 30% of the lateral span, and more preferably at positions between 5% and 20% of the lateral span.

68. The pleated filter media packaging according to claim 67, wherein, The lateral span of the non-middle region is at least 200% of the maximum width of the slender embossed pattern, and the lateral span of the middle region is preferably between 200% and 600% of the maximum width of the slender embossed pattern.

69. The filter media packaging of claim 63, further comprising at least one feature in combination with the offset alignment, said at least one feature being any one or more of: (a) a saddle formed into the elongated embossing; (b) a bridging embossing formed into the intermediate region; or (c) an angled alignment of the elongated embossing.

70. The filter media packaging of claim 63, wherein the elongated embossing extends between 75% and 99% of the span of the panel between the inlet flow surface and the outlet flow surface, and more preferably between 95% and 99% of the span of the panel between the inlet flow surface and the outlet flow surface, and wherein the panel extends between the inlet flow surface and the outlet flow surface for a span between 7 and 45 cm, more preferably between 10 and 35 cm.

71. The filter media packaging according to claim 63, wherein the filter media sheet comprises a blend of fibers including cellulose fibers and synthetic polymer fibers, wherein the blend of fibers comprises more than 50% cellulose fibers by weight percentage; and more preferably between 70%-90% cellulose fibers and 10%-30% synthetic polymer fibers; and most preferably between 75%-85% cellulose fibers and 15% to 25% synthetic polymer fibers.

72. The filter media packaging according to claim 63, wherein the maximum depth of the elongated embossing is between 1.0 and 4.5 mm, more preferably between 1.0 and 2.0 mm, and most preferably between 1.3 and 1.6 mm.

73. The filter media packaging according to claim 63, wherein within the internal region of the filter media packaging, the lateral span of the intermediate region is at least 200% of the lateral span of each of the elongated embossings, more preferably between 200% and 600%, and most preferably between 225% and 325%.

74. The filter media packaging according to claim 63, wherein, In the filter media package, all the elongated embossed surfaces face the same direction. The filter media package has a continuously alternating first panel and a second panel, wherein the elongated embossing on the first panel protrudes outward from a first side of the filter media sheet, and the elongated embossing on the second panel protrudes outward from a second side of the filter media sheet opposite to the first side.

75. A filter media package, comprising: Multiple panels of filter media extending laterally between an inlet flow surface and an outlet flow surface, the multiple panels being arranged generally in parallel, and each panel having a first side and a second side opposite to the first side; Multiple elongated embossed patterns are formed in the panel and extend longitudinally between the inlet flow surface and the outlet flow surface. The elongated embossed patterns are laterally spaced and separated by intermediate regions, each intermediate region being between a corresponding pair of elongated embossed patterns. as well as A bridging embossing is formed in the intermediate region and extends laterally between adjacent members of the elongated embossing.

76. The filter media packaging according to claim 75, wherein, The plurality of panels are connected in a single continuous sheet folded into a pleated structure, wherein the filter media package is a pleated filter media package.

77. The filter media packaging according to claim 75, wherein, The filter media package has virtually all panels with elongated embossing formed therein.

78. The filter media packaging of claim 75, wherein the elongated embossing extends between 75% and 99% of the span of the panel between the inlet flow surface and the outlet flow surface, and more preferably between 95% and 99% of the span of the panel between the inlet flow surface and the outlet flow surface, and wherein the panel extends between the inlet flow surface and the outlet flow surface for a span between 7 and 45 cm, more preferably between 10 and 35 cm.

79. The filter media packaging according to claim 75, wherein the filter media sheet comprises a blend of fibers including cellulose fibers and synthetic polymer fibers, wherein the blend of fibers comprises more than 50% cellulose fibers by weight percentage; and more preferably between 70%-90% cellulose fibers and 10%-30% synthetic polymer fibers; and most preferably between 75%-85% cellulose fibers and 15% to 25% synthetic polymer fibers.

80. The filter media packaging according to claim 75, wherein the maximum depth of the elongated embossing is between 1.0 and 4.5 mm, more preferably between 1.0 and 2.0 mm, and most preferably between 1.3 and 1.6 mm.

81. The filter media packaging according to claim 75, wherein within the internal region of the filter media packaging, the lateral span of the intermediate region is at least 200% of the lateral span of each of the elongated embossings, more preferably between 200% and 600%, and most preferably between 225% and 325%.

82. The filter media packaging according to claim 75, wherein, In the filter media package, all the elongated embossed surfaces face the same direction. The filter media package has a continuously alternating first panel and a second panel, wherein the elongated embossing on the first panel protrudes outward from a first side of the filter media sheet, and the elongated embossing on the second panel protrudes outward from a second side of the filter media sheet opposite to the first side.

83. The filter media packaging of claim 75, further comprising at least one feature in combination with the bridging embossing, said at least one feature being any one or more of the following: (a) a saddle formed into the elongated embossing; (b) an offset alignment of the embossing away from the midpoint of the intermediate region; or (c) an angular alignment of the elongated embossing.

84. The filter media packaging of claim 75, wherein the bridging embossing extends laterally between adjacent members of the elongated embossing by more than 50% of the lateral span, and preferably between 70% and 110% of the lateral span, and most preferably the bridging embossing completely spans the intermediate region, connecting adjacent members of the elongated embossing.

85. The filter media packaging of claim 75, wherein the bridging embossing is included in at least 75% and preferably 90%-100% of the intermediate region between adjacent members of the elongated embossing, and most or all of the panel has elongated embossing.

86. The filter media packaging of claim 75, wherein on each panel, the bridging embossing and the elongated embossing project outward from opposite sides of the filter media sheet.

87. The filter media packaging according to claim 86, wherein, In the pleated filter media package, all elongated embossed surfaces face the same direction, and the filter media package has continuously alternating first and second panels, wherein: (a) The elongated embossing on the first panel protrudes outward from a first side of the filter media sheet, and the elongated embossing on the second panel protrudes outward from a second side of the filter media sheet opposite to the first side; and (b) The bridging embossing on the first panel protrudes outward from the second side of the filter media sheet, and the bridging embossing on the second panel protrudes outward from the first side of the filter media sheet opposite to the second side.

88. The filter media packaging of claim 75, wherein the elongated embossing on the first panel contacts the bridging embossing of the second panel adjacent to the first panel.

89. The filter media packaging of claim 75, wherein the bridging embossing defines the bridging width and bridging depth, and wherein: (a) The bridging width is between 10% and 50% of the maximum width of the slender embossing, and more preferably between 20% and 40% of the maximum width of the slender embossing; and The bridging depth is between 10% and 50% of the maximum depth of the elongated embossing, and more preferably between 20% and 40% of the maximum depth of the elongated embossing.

90. The filter media packaging of claim 75 further includes a pair of formed gusset plates integrally connecting the bridging embossing to the elongated embossing.

91. The filter media packaging of claim 75, wherein the bridging embossing is an elongated bridging embossing, the elongated bridging embossing defining a bridging length / span between adjacent members of the elongated embossing and a bridging width perpendicular thereto, wherein the bridging width is between 1 mm and 3 mm, more preferably between 1 mm and 2 mm; and wherein the bridging length / span is between 4 mm and 36 mm, more preferably between 8 mm and 20 mm; and wherein the maximum bridging embossing depth is between 0.2 mm and 1.0 mm, more preferably between 0.3 mm and 0.8 mm.

92. The filter media packaging of claim 75, wherein all panels including elongated embossing further include bridging embossing.

93. A filter media package, comprising: Multiple panels of filter media extending laterally between an inlet flow surface and an outlet flow surface, the multiple panels being arranged generally in parallel, and each panel having a first side and a second side opposite to the first side; Multiple elongated embossed patterns are formed in the panel and extend longitudinally between the inlet flow surface and the outlet flow surface. The elongated embossed patterns are laterally spaced and separated by intermediate regions, each intermediate region being between a corresponding pair of elongated embossed patterns. as well as The elongated embossed pattern is angled, wherein the elongated embossed pattern extends at an oblique angle relative to the fold and provides intermittent contact points.

94. The filter media packaging according to claim 93, wherein, The plurality of panels are connected in a single continuous sheet folded into a pleated structure, wherein the filter media package is a pleated filter media package, and wherein the elongated embossing stops before reaching the folds of the pleated structure.

95. The filter media packaging according to claim 93, wherein, The filter media package has virtually all panels with elongated embossing formed therein.

96. The filter media packaging of claim 93, wherein the elongated embossing extends between 75% and 99% of the span of the panel between the inlet flow surface and the outlet flow surface, and more preferably between 95% and 99% of the span of the panel between the inlet flow surface and the outlet flow surface, and wherein the panel extends between the inlet flow surface and the outlet flow surface for a span between 7 and 45 cm, more preferably between 10 and 35 cm.

97. The filter media packaging according to claim 93, wherein the filter media sheet comprises a fiber blend containing cellulose fibers and synthetic polymer fibers, wherein the fiber blend comprises more than 50% cellulose fibers by weight percentage; and more preferably 70%-90% cellulose fibers and 10%-30% synthetic polymer fibers; and most preferably between 75%-85% cellulose fibers and 15% to 25% synthetic polymer fibers.

98. The filter media packaging according to claim 93, wherein the maximum depth of the elongated embossing is between 1.0 and 4.5 mm, more preferably between 1.0 and 2.0 mm, and most preferably between 1.3 and 1.6 mm.

99. The filter media packaging according to claim 93, wherein within the internal region of the filter media packaging, the lateral span of the intermediate region is at least 200% of the lateral span of each of the elongated embossings, more preferably between 200% and 600%, and most preferably between 225% and 325%.

100. The filter media packaging of claim 93, further comprising at least one feature combined with the angled alignment, said at least one feature being any one or more of the following: (a) a saddle formed into the elongated embossing; (b) an offset alignment of the embossing away from the midpoint of the intermediate region; or (c) a bridging embossing formed into the intermediate region.

101. The filter media packaging according to claim 93, wherein the elongated embossing protrudes at an angle between 2 and 10 degrees relative to the pleats, and more preferably at an angle between 3 and 8 degrees, and most preferably at an angle of about 5 degrees.

102. The filter media packaging according to claim 93, wherein the elongated embossed linear extension is defined.

103. The filter media packaging according to claim 93, wherein, The elongated embossing is formed into the filter media sheet along a common inclined direction, wherein, in a folded arrangement, the elongated embossing on adjacent panels is angled along opposite inclined directions.

104. The filter media packaging according to claim 103, wherein the elongated embossing is spaced apart from the folds in the folded arrangement.

105. The filter media packaging according to claim 93, wherein at least one set of elongated embossed patterns are formed parallel to each other in the filter media sheet.

106. The filter media packaging according to claim 105, wherein, All the slender embossed patterns are formed parallel to each other in the filter media sheet.

107. The filter media packaging of claim 93, wherein the first array of elongated embossings protrudes outward from a first side of the filter media sheet, and the second array of elongated embossings protrudes outward from a second side of the filter media sheet opposite to the first side, and wherein the embossings are angled along a common direction as formed in the filter media sheet, such that when folded on top of each other, the elongated embossings on adjacent panels are angled relative to each other in opposite directions.

108. The filter media packaging according to claim 93, wherein, Each of the elongated embossings terminates before reaching a pleated portion that provides a pleated filter media package, and wherein a linear crisscross provides the pleated portion.

109. The filter media packaging according to claim 108, wherein, Each of the elongated embossed patterns is spaced apart from the pleats, thus stopping before reaching the pleats.

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