Enhancement of fuel water separation using structural embossing

Abstract

To provide a relevant filtration medium indicating a reduced pressure difference while providing an advantage such as water aggregation, for a hydrocarbon fuel system and an aggregation filtration system used in the application, a method for manufacturing the same, a method for filtering water, and a filtration system.SOLUTION: A filter medium provides improved filter characteristics including water separation efficiency. The filter medium may include one or both of increased surface roughness and embossing. The filter medium may be provided by a pleat-like filter medium.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates generally to filtration, and more particularly to, for example, hydrocarbon fuel systems and This invention relates to a flocculation and filtration system for use in the following applications: [Background technology]

[0002] Coalescence filtration systems often use a first stage to filter hydrocarbon fluids, e.g., fuels. Employed in a filter / separator vessel. Such systems filter out specific contaminants. It removes the water particles and causes the highly dispersed and emulsified water particles to coalesce (combine) into larger droplets. These larger droplets are then collected and removed from the system.

[0003] Various methodologies have been employed to achieve such agglomeration. Small droplets of water trapped within the filter media (e.g., glass fiber) contact the strands. The operating pressure and fluid flow in the system create twisted droplets that can bond with other droplets. These twisted yarns are twisted together until the droplets reach the intersection of the yarns and coalesce into larger droplets. The droplet is pushed along the

[0004] The embossed patterns are often compression molded into the filter media. The turns often extend parallel to the flow direction, making the fluid flow parallel to the embossing. This leads to a lower embossed contact area with the water droplet. For example, a filter with a vertical central axis In radial flow filters using tubes of carbon media, the elongated embossments are typically The filter media has an elongated axis parallel to the radius of the tube perpendicular to the axis. In this case, the filter is generally drawn through the block of filter media from the upstream face of the block of filter media. The flow is parallel to the fluid flow leading to the downstream face of the filter media block.

[0005] In use, the coalesced water droplets move along the filter media, e.g., along the central axis of the filter media tube. The water flows parallel to the filter media tube and into the water collection bowl. As you move from the top to the bottom of the filter media tube, the water concentration increases continuously, forming droplets. The water becomes highly concentrated at the bottom of the element before being collected in the water collection bowl. Summary of the Invention [Problem to be solved by the invention]

[0006] Although the above system has been found to be satisfactory, there remains room for improvement. In fact, there is a continuing desire to reduce the pressure drop across the filter element. The drop is typically driven by the filter media used in the filter element. , filtering elements, and still provide the advantages of fuel-water separation, i.e., water condensation. There is a need in the art for related filtration media that exhibit reduced pressure differentials while providing high-performance filtration. [Means for solving the problem]

[0007] This application is directed not only to such filter elements and associated filter media, but also to the devices that form them. This application offers improvements over the current state of the art.

[0008] In one embodiment, a pleated filter includes a filtration medium having pleated sides with structural embossing. The filter element is provided by pleating the filter medium and providing a selected filter element between successive pleat sides. a plurality of longitudinally extending adjacent opposing continuous pleats of varying depth and spacing; providing spaced apart upstream and downstream filter surfaces; The pleat sides are connected by corresponding fold lines. Each of the consecutive pleat sides comprises a first At least one of the first side and the second side on the adjacent side faces is A plurality of structural embossings are formed on one side. The structural embossings are formed on adjacent Different geometries between structural embossments, different filtration media between adjacent embossments on the side Different protrusions along at least one of the first side and the second side relative to the longitudinal axis. angles, non-polygonal configurations, teardrop geometries, and / or first and second ends. a portion defining an embossing axis extending between a first end and a second end, the portion having a corresponding The embossing axis extends in a non-parallel and non-perpendicular orientation to the fold line connected to the pleat side. The flexible substrate has at least one of a first end and a second end.

[0009] In one example, a pleated filter media having a plurality of pleated sides and a plurality of structural embossments is provided. The pleated filter element includes a body, the pleated filter media defining an upstream surface. The pleated filter media has a first side and a second side that forms a downstream surface. The folds are made of a single piece of paper, and each piece has a side and a plurality of folds. The pleated side surfaces are connected to each other. Each structural embossment is formed by the structural embossing. The boss has a first end and a second end that define a boss axis. The folds extend in a non-parallel and non-perpendicular orientation to the folds connected to the pleat sides.

[0010] In one example, pleated filter media forms a tube of filter media defining a central longitudinal axis. The folds run parallel to the longitudinal central axis. Each structural embossment The embossing is elongated along the embossing axis.

[0011] In one example, a first pleat side of the plurality of pleat sides includes a plurality of structural embossments. A first structural embossing and a second structural embossing among the plurality of structural embossings The embossing axis of the first structural embossing is connected to the second structural embossing. It extends at a different angle to the embossing axis of the process.

[0012] In one example, the pleated filter media has a gravity top and a gravity bottom. is (for example, when in use) vertically above the bottom of gravity. The fold is The embossing axis of the first structural embossing extends between the sections of the second structural embossing. The first structural embossing is less aligned with gravity than the embossing axis of the first Located closer to the top of gravity than the structural embossing of 2.

[0013] In one example, pleated filter media comprises blocks of filter media defining an upstream surface and a downstream surface. The block of filter media forms a block where the fluid to be filtered flows from the upstream surface to the downstream surface. The flow direction is generally perpendicular to the folds.

[0014] In one example, the embossing axis moves in the direction of flow from the upstream surface to the downstream surface. The embossing axis moves upward toward the gravitational top of the pleated filter media. At an angle to the eye.

[0015] In one example, a second pleat side of the plurality of pleat sides includes a plurality of structural embossments. A third structural embossing is formed. A plurality of folds are formed between the first pleat side and the second pleat side. A first fold is formed in the crease. A first structural embossing is formed along the first fold. A third structural embossment is formed between the first end and the first end of the second structural embossment. The first end is axially positioned. The first end and the second end of the third structural embossing are aligned. A first end of a second structural embossing is axially positioned between the first and second structural embossings.

[0016] In one example, the first, second, and third structural embossings may be formed to specifically target fluid flow. When viewed in the direction of the arrow, the alignments are arranged so as to overlap.

[0017] In one example, each of the plurality of structural embossments has a width generally perpendicular to the embossing axis. The width increases when moving from the first end towards the second end.

[0018] In one example, the depth / height of the structural embossing varies from the first end to the second end. It increases when moving.

[0019] In one example, the first structural embossing and the second structural embossing may be pleated fillets. The pleated filter media has a protrusion on a first side thereof and a recess on a second side thereof. The third structural embossing is a protrusion on the second side of the second pleat side and a first protrusion on the second pleat side. Form a depression on side 1.

[0020] In one example, the filtration media is formed into a tube of pleated filter media defining a central longitudinal axis. Each of the structural embossments is formed on one of the first side and the second side of the corresponding pleat side. A protrusion is formed on one side, and a depression is formed on the other side of the first and second sides of the corresponding pleat. The width of the protrusions and depressions measured generally perpendicular to the corresponding axes of the structural embossings. The depth of the pleated filter media tube embossed radially away from the central longitudinal axis It increases when moving along the axis.

[0021] In one example, the width of the protrusions measured generally perpendicular to the corresponding axis of the structural embossing and The depth of the dimples is measured radially away from the central longitudinal axis of the pleated filter media tube. It increases when moving along the machining axis.

[0022] In one example, the pleated filtration media is formed in a tube of pleated filter media. The tube of media defines a central longitudinal axis. The tube of pleated filter media is configured to pass through the fluid to be filtered. is configured to flow radially through the tube of pleated filter media as it is filtered. The separated water moves generally parallel (more parallel) to the central longitudinal axis. The tube of the filter medium has a gravitational top and a gravitational bottom. The gravitational top is the vertical axis of the gravitational bottom. The central longitudinal axis and folds extend between the top and bottom of the gravity center. The embossing axis of the structural embossing is the overlapping of the The force is oriented along the longitudinal axis toward the bottom. The embossing axis is oriented radially outward. However, other embodiments have the opposite orientation. good.

[0023] In one embodiment, there is provided a method of making the filter element as outlined above. providing a filter media; and embossing the filter media with a plurality of structural embossments. and folding the filter media at multiple folds to form multiple pleated sides. and

[0024] In one embodiment, a method for filtering water from a fuel stream is provided. The method comprises: The filter media of the filter element is exposed to the air as it flows from the inlet of the filter element to the outlet of the filter element. The method includes passing a flow of fuel through the fuel tank.

[0025] In one embodiment, the filter head, housing, and filter element are as outlined above. The filter head has an inlet and an outlet. The housing defines a drainage receiving area. The housing includes at least a portion of a filter element as described above. is positioned inside the enclosure vertically above the drain receiving area and is fluidly positioned between the inlet and outlet put.

[0026] In one embodiment, a method of making a filter media is provided, the method comprising: forming a surface with a predetermined roughness; The method includes providing a layer of filtration media having a selected roughness. and contacting the surface of the medium to provide the surface of the medium with a roughness greater than a predetermined roughness. Includes:

[0027] The device may be a roller, plate, belt, or other structure to provide an enhanced surface roughness. The device may also include structure for forming the structural embossing.

[0028] In one embodiment, the method includes compressing the medium using an apparatus, whereby: Enhanced surface roughness or structural embossing can be created.

[0029] In one embodiment, the method includes the step of pleating the media after it contacts the device. nothing.

[0030] In one embodiment, the method includes forming a structural embossment in a surface of the media layer. include.

[0031] In one embodiment, the step of pleating the medium includes forming fold lines between adjacent pleated panels. The method includes forming a plurality of structural embossments, each of the plurality of structural embossments having a first end and a second end. The embossing axis extends between the first and second ends. The method includes forming a plurality of elongated structural embossments, the embossing shaft comprising: It stretches in an orientation that is non-parallel and non-perpendicular to the fold lines.

[0032] In one embodiment, the first structural embossing and the second structural embossing of the plurality of structural embossings A second structural embossing is formed in the first pleated panel. The embossing axis is different from the embossing axis of the second structural embossing relative to the fold line. Extends at an angle.

[0033] In one embodiment, the filter element has a gravity top and a gravity bottom. The embossing axis of the first structural embossing is vertically above the bottom of gravity. The structural embossing is less aligned with gravity than the embossing axis of the embossing.

[0034] In one embodiment, the third structural embossing in the plurality of structural embossings is Forming a fold line within the pleat panel. Forming a fold line between the first pleat panel and the second pleat panel. Between the first end of the first structural embossing and the first end of the second structural embossing A first end of the third structural embossing is axially positioned along the fold line, and the third A first end of the second structural embossing is formed between the first end and the second end of the structural embossing. The end is positioned axially.

[0035] In one embodiment, the plurality of structural embossments are each generally aligned along a structural embossment axis. The width increases as you move from the first end to the second end. In some embodiments, this forms the filter media into a tube of pleated filter media. In other embodiments, this is simply a panel filter. It may be generally downstream, such as within the element, e.g., from the upstream face of the filter media pack. It may reach the downstream surface.

[0036] In one embodiment, the first structural embossing and the second structural embossing are formed by filling forming protrusions on a first side of the layer of filter media and depressions on a second side of the filter media. The structural embossing of the filter media forms protrusions on the second side of the filter media and protrusions on the first side of the filter media. A recess is formed.

[0037] In one embodiment, the surface of the media is contacted with an instrument having a selected roughness to form a surface of the media. The step of providing a roughness greater than a predetermined roughness to a filler that does not include structural embossing is The process is carried out in at least 80% of the filter medium, more preferably at least 90%.

[0038] In one embodiment, the increased surface roughness, fold lines, and / or structural embossing may be At least 95% of the surface of the filtration media was engineered to contain at least one of the following:

[0039] In one embodiment, the roller or plate has a thickness of at least 35μ, more preferably at least It has a surface roughness of 190μ.

[0040] In one embodiment, the filter media has an enhanced surface roughness of 20 microns, more preferably It is at least 100μ.

[0041] In one embodiment, the surface of the media is contacted with an instrument having a selected roughness to form a surface of the media. providing a roughness greater than a predetermined roughness to the filter media by removing material from the filter media. Carry out without any effort.

[0042] In one embodiment, the surface of the media is contacted with an instrument having a selected roughness to form a surface of the media. The step of providing a roughness greater than a predetermined roughness to the filter medium is referred to as compressing the filter medium to provide a roughness greater than a predetermined roughness. This is accomplished by creating roughness.

[0043] In one embodiment, the surface of the layer of filter media is an exposed surface. The upstream surface of the

[0044] In one embodiment, the layers of filter media are pre-laminated media formed from multiple media layers. The surface of the medium is brought into contact with an instrument having a selected roughness to produce a predetermined roughness on the surface of the medium. The step of providing a roughness greater than the roughness of the filter medium may include forming a plurality of layers of the filter medium. The media layers are not fixed at the same time.

[0045] In certain implementations, the filter media may be laminated prior to undergoing any surface roughness enhancement treatment. The filter media is unwound from a roll of filter media in a sealed state.

[0046] In one embodiment, the surface is then contacted with an instrument having a selected roughness on the surface of the medium. The coating may be performed after the step of providing the surface of the medium with a roughness greater than a predetermined roughness. It is not covered.

[0047] In one embodiment, the surface roughness of the filter media layer is between 130° and 140°, preferably was measured using a goniometer with water at 132°C. It has a contact angle.

[0048] In one embodiment, a filter element is provided. The filter element is formed from layers of filtration media. The pleated filter media pack includes a layer of filtration media formed by a plurality of fold lines. The plurality of pleated panels are formed. The filtration media has an upstream surface and a downstream surface. The upstream surface is compressed to have a surface roughness.

[0049] In one embodiment, the surface roughness of the upstream surface is greater than the surface roughness of the downstream surface.

[0050] In one embodiment, the fluid to be filtered is first contacted with the upstream surface of the layer of filtration media. The upstream surface of the layer of filtration media is exposed. Therefore, the surface that provides the desired roughness is Furthermore, the cracks or voids that form the surface roughness are not located between different layers of the material. It is not filled with food.

[0051] In one embodiment, the layer of filtration media includes a structural embossing in the upstream surface of the media layer.

[0052] In one embodiment, the plurality of structural embossings comprises: a first end and a second end defining an embossing axis extending between the first end and the second end; The embossing axis is arranged non-parallel and non-perpendicular to the fold line. It extends in the opposite direction.

[0053] In one embodiment, the first structural embossing and the second structural embossing of the plurality of structural embossings A second structural embossing is formed in the first pleated panel. The embossing axis is different from the embossing axis of the second structural embossing relative to the fold line. Extends at an angle.

[0054] In one embodiment, the filter element has a gravity top and a gravity bottom, the gravity top , vertically above the bottom of gravity. The embossing axis of the first structural embossing is The structural embossing axis is less aligned with gravity than the first structural embossing axis. The embossing is vertically above the second structural embossing.

[0055] In one embodiment, the third structural embossing in the plurality of structural embossings is Forming a fold line within the pleat panel. Forming a fold line between the first pleat panel and the second pleat panel. Between the first end of the first structural embossing and the first end of the second structural embossing A first end of the third structural embossing is axially positioned along the fold line, and the third A first end of the second structural embossing is formed between the first end and the second end of the structural embossing. The end is positioned axially.

[0056] In one embodiment, upstream and downstream fold lines (e.g., radially outward fold lines within a cylindrical element) are Position the first, second, and third embossings between the fold line and the radially inner fold line. Decide on a location.

[0057] In one embodiment, the first, second, and third fold lines are located at the same location between the upstream fold line and the downstream fold line. Position the embossing in step 3.

[0058] In one embodiment, the first, second, and third embossments are aligned with one another along the fold line. The shaft is misaligned.

[0059] In one embodiment, the plurality of structural embossments are each generally perpendicular to the embossing axis. The width increases as you move from the first end to the second end. In one embodiment, this increase in width occurs toward the downstream fold line (e.g., toward the panel filter element). radially inward within the cylindrical filter element as it moves from the upstream surface toward the downstream surface of the element; or through a media pack).

[0060] In one embodiment, the first structural embossing and the second structural embossing are formed by filling forming protrusions on a first side of the layer of filter media and depressions on a second side of the filter media. The structural embossing of the filter media forms protrusions on the second side of the filter media and protrusions on the first side of the filter media. A recess is formed.

[0061] In one embodiment, at least 80% of the filter media does not contain structural embossing; Preferably, at least 90% of the surface roughness is greater than the surface roughness of the structural embossing. Has.

[0062] In one embodiment, the increased surface roughness, fold lines, and / or structural embossing may be At least 95% of the surface of the filter media was engineered to contain at least one of the following:

[0063] In one embodiment, the surface roughness of the upstream surface is at least equivalent to 120 grit sandpaper. The thickness should be 116μ, and more preferably at least 190μ, equivalent to 80-grit sandpaper. and even more preferably at least 425μ, equivalent to 40-grit sandpaper. do.

[0064] In one embodiment, the surface roughness of the upstream surface is at least that of 120 grit sandpaper. At least equivalent to, and more preferably at least equivalent to, the surface roughness of 80-grit sandpaper and even more preferably at least equivalent to 40 grit sandpaper.

[0065] In one embodiment, the saturation is increased to at least 50% greater than in the unoperated state. more preferably at least 100% greater than in the unmanipulated state, More preferably, the upstream surface is at least 400% larger than in the unoperated state. The surface roughness of the face was manipulated.

[0066] In one embodiment, the filtration media is removed by removing material from the upstream surface, rather than by removing material from the upstream surface. Compressing the flow surface provided surface roughness on the upstream face of the layer of filter media.

[0067] In one embodiment, the upstream surface of the layer of filtration media is an exposed surface that forms a surface roughness. The voids in the upstream surface may be filled or coated with other materials. This is because folding the filter media at the pleat crease may cause adjacent pleat panels to overlap. does not necessarily entail.

[0068] In one embodiment, the layer of filtration media is independent of the structure of the filtration media that provides the surface roughness on the upstream surface. A pre-laminated media formed from multiple media layers fixed together in a fixed relationship.

[0069] In one embodiment, the surface roughness of the filtration media layer is between 130° and 140°, preferably less than 150°. The surface has a contact angle measured using a goniometer with water of at least 132°.

[0070] In one embodiment, a method for filtering water from a fuel stream comprises: When flowing from the inlet to the outlet of the filter element, any one of the embodiments outlined above The method includes passing a flow of fuel through a filtering medium of a filter element.

[0071] In some embodiments, the filter head has an inlet and an outlet, and the filter head defines a drain receiving area. and a filter element according to any one of the preceding embodiments. The filter element is located at least partially within the housing vertically above the drainage receiving area. The fluid is placed between the inlet and outlet.

[0072] Other aspects, objects, and advantages of the present invention are set forth below when taken in conjunction with the accompanying drawings. This will become more apparent from the detailed description.

[0073] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate several aspects of the present invention. which, together with the present specification, serve to explain the principles of the present invention. [Brief explanation of the drawings]

[0074] [Figure 1] 1 is a simplified diagram of a filter element. [Figure 2] 2 is a simplified illustration of a pair of pleated panels after processing but before folding (pleating) for use in the filter media of the filter element of FIG. 1; [Figure 3] 3 is a simplified cross-sectional view of FIG. 2 taken along line 3-3. [Figure 4] 1 is a simplified diagram of a system for manipulating filter media to form a pleated array including structural embossing and increased surface roughness. [Figure 5] 1 is a photograph of a filter media prior to pleating according to an application implementation including structural embossing and optional enhanced surface roughness. [Figure 6] 1 is a photograph of a filter media before pleating (eg, folding) according to an implementation of the application including structural embossing but without optional enhanced surface roughness. [Figure 7] FIG. 7 is a photograph of a control sample of filter media that did not include enhanced surface roughness or embossing, as used for the filter media of FIGS. 5 and 6. [Figure 8] 8 is an image of the contact angle of a water droplet on a control sample of the filter media of FIG. 7. [Figure 9] 6 is an image of the contact angle of a water droplet on the enhanced surface roughness region of the sample of FIG. 5. [Figure 10] 8 shows test results comparing the samples of FIGS. 5 to 7. [Figure 11] 8 shows test results comparing the samples of FIGS. 5 to 7. [Figure 12] 8 shows test results comparing the samples of FIGS. 5 to 7. [Figure 13] 2 is a simplified filtration system utilizing a filter element according to FIG. 1, further including a filter head and a removable collection bowl. [Figure 14] 1 is a simplified illustration of the flow of fluid to be filtered through an area of filter media formed in accordance with the present application, as well as the flow of water separated from the fluid. DETAILED DESCRIPTION OF THE INVENTION

[0075] Although the present invention will be described in connection with certain preferred embodiments, No limitation of the present invention is intended. On the contrary, the present invention is defined by the appended claims. All alternatives, modifications, and equivalents as fall within the spirit and scope of the present invention are intended to be included herein. It is intended to cover forms.

[0076] FIG. 1 illustrates a simplified filter element 100 incorporating the teachings of the present application. The filter element 100 is formed in a block of pleated filter media, specifically a cylindrical tube. The pleated filter media 102 (also referred to as "filtration media") is a cylindrical Although pleated filter media 102 within a flat tube is illustrated, other embodiments according to the present teachings may be The filter media can be formed into a block of filter media in the form of a panel of filter media. Cut.

[0077] The filter element 100 is particularly useful in filtering water from a fluid stream, such as a fuel stream. The filter element 100 may also filter certain substances from the fluid stream.

[0078] The dirty fluid is introduced into the filter through one or more inlets, illustrated by arrows 104. The dirty fluid enters the filter media 100. As the fluid flows through the filter media 102, Through the filter media 102, the upstream surface (radially within the cylindrical tube of the filter media) Flow from the outside (outside) to the downstream surface (radially inward in a cylindrical tube, such as the filter media) After passing through the filter media 102, the cleaned fluid flows out as illustrated by arrow 106. Flows through one or more outlets.

[0079] The filter media 102 preferably has a filter layer 104 formed therein such that the aggregated water droplets 110 are separated from the fluid. It is configured to condense water entrained within the unfiltered fluid. 10 flows, as illustrated by arrow 112, into a drain pan 114 or other collection site. The flow of the droplets 110 is generally parallel to the force of gravity (illustrated by arrow 124).

[0080] FIG. 13 illustrates a filtration system in which the filter element 100 may have particular applicability. In this case, a removable filter head 121 is detachably connected to the filter head 115. A drain catcher 114 is provided by a flexible bowl 117. The filter head 121 has an inlet 1 04 and an outlet 106 are provided.

[0081] The filter media 102 is one or more layers of filter media, one of which is Folding the layers to define fold lines separating adjacent pleat panels 122 The folds 120 form a pleated layer of filter media. The pleat panels 122 are interconnected in adjacent pairs (also called side panels). In other words, the folds 120 are generally parallel to the force of gravity, illustrated by arrows 124 in FIG.

[0082] Preferably, the water drain pan 114 is located at the bottom end 130 of the filter media 102. On the other hand, the outlet 106 is at the top end 132, where "top" and "bottom" are The "parts" are defined with reference to gravity. In this way, gravity is used to determine the size of the coalesced droplets. 110 can be directed towards a water drain pan 114 rather than towards the outlet 106. .

[0083] As noted, the filter media 102 preferably has pleat folds 120 arranged in a plurality of pleats. The inner surface of the inner periphery of the inner periphery is formed from pleated media separating the inner periphery of ...

[0084] FIG. 2 shows this embodiment before folding along fold lines 120 provided by score lines during the manufacturing process. 1 is a top view of a pair of pleat panels 122A, 122B. 22B, but also separates the pleat panel 122A from the two adjacent pleat panels 12 2A and 122B are interconnected.

[0085] In a tubular filter element such as that of FIG. 1, pleats (which may be provided by score lines before folding) The eye 120 is made up of radially outer pleat folds 120A and radially inner pleat folds 120B. B (e.g., the radially outer pleat fold 120A is called the upstream pleat fold) The radially inward pleat fold 120B may be formed as illustrated by arrow 104 in FIG. These are sometimes called downstream folds, which involve radial fluid flow from the outside to the inside. The pleat panel 122 generally has an outer pleat fold 120A and an inner pleat fold 120B. B) radially extend (typically at a slight angle from completely radial). The side pleat folds 120A are radially aligned (illustrated by dotted lines 119A) of the filter media tube. can be thought of as forming the outer periphery or upstream face of the 120B is a radially inner periphery (illustrated by dotted line 119B) of the filter media tube. or downstream surface.

[0086] In a panel filter element, the pleat fold 120A forms the upstream surface of the panel filter; On the other hand, the pleat fold 120B forms the downstream surface of the panel filter element. 122 generally extends between the upstream and downstream faces.

[0087] Referring to FIG. 2, the filter media also includes a plurality of structural embossments 140A, 140B. B. A structural embossing 140A is formed in the pleat panel 122A, while the structural A structural embossment 140B is formed in the pleat panel 122B.

[0088] FIG. 2 shows two pleated panels 122A, 122B of filter media 102 prior to folding at fold line 120. 22B (see also FIG. 3), the upstream surface 142 is In operation, the contaminated fluid first contacts the upstream surface 142 and then The cleaned fluid passes through the filter media 102 and exits the filter media through downstream surface 144. Exit body 102.

[0089] The filter media has multiple operations according to an embodiment of the present application. The first operation is a cut operation. The purpose of this is to form pleats 120 which may be folds or creases.

[0090] The second operation is to form the structural embossings 140A, 140B. 3, in this embodiment, embossments 140A are formed on the filter media 10. 2, a plurality of recesses in the upstream surface 142 of the filter media 102, and a plurality of recesses in the downstream surface 144 of the filter media 102. The embossing 140B is a concave embossing that forms a raised portion of the upstream surface. a plurality of protrusions in the downstream surface 142 and a plurality of depressions in the downstream surface 144; It is boss processing.

[0091] This embodiment has pleated panels 12 that alternate between raised and lower embossing. 2. In some embodiments, , all embossings can be convex, or all of the embossings can be concave Additionally, in some embodiments, the single pleat panel 122 may be convex. It can have both embossed and recessed embossed.

[0092] Each of the embossments 140 includes a first end 146 and a second end 148. The boss 140 has a first end 146 and a second end 148 along an embossing axis 150. It extends longitudinally between the

[0093] In the exemplary embodiment of FIG. 2, the embossing is at the first end 146 and the second end 148. Specifically, the embossing 140 (FIG. The width W (illustrated by the double arrow in FIG. 2) changes from the first end 146 to the second end 148. In other embodiments, the width increases as the can remain constant and need not increase as one moves radially inward.

[0094] At least a portion of each embossment 140 is at least twice as thick as the filter media. , preferably having a width W that is at least three times the thickness of the filter media. In this case, at least a portion of some or all of the embossings is located on the filter media. It has a width W that is at least four times the thickness.

[0095] In some implementations, the height H of the embossment 140 is This increases as you move from one end of the embossing to the other. As such, the height H increases as you move away from the fold 120 along the embossing axis 150. Although described in terms of height H, the depth of the concave embossing increases with the increase in the At least a portion of each embossment 140 may be formed on at least one surface of the filter media. has a height H that is at least twice as thick as the filter media, and preferably at least three times as thick as the filter media In some embodiments, at least a portion of some or all of the embossings , having a height H that is at least four times the thickness of the filter media.

[0096] In some embodiments, the pleat panel 122 has a second end 14 of the embossing 140. 8 is positioned radially closer to the central axis 150 of the tube of filter media 102. The flat panel filters are folded against each other at crease 120. 40 is generally measured from the upstream face of the panel to the downstream face (e.g., through the filter media panel). However, in other embodiments, the first The orientation of the first end 146 and the second end 148 of the embossment 140 is such that the second end 148 is radially farther from the central axis 150 of the tube of filter media 102 than the first end 146. The positioning can be switched to

[0097] This angled orientation prevents the contaminated fluid from reaching the upstream surface 142 of the filter media 102, specifically As it flows across the embossments 140, it helps to coalesce any entrained water. The processing also maintains spacing between adjacent pleat panels 122A and 122B when folded. It is useful.

[0098] Referring to FIG. 2, in addition to tapering, in some embodiments, the embossed shaft 150 , stretched in an orientation non-parallel and non-perpendicular to the fold 120 and gravity 124. The non-parallel and non-perpendicular orientation is the overlapping pattern when viewed in the radial direction. This creates a barrier layer that helps reject more water droplets 110 from entering the medium. .

[0099] FIG. 14 is a cross-sectional view of the filter media 10 that better illustrates the overlapping pattern. This is a simplified diagram of 2.

[0100] In a preferred configuration, when transitioning from the top end 132 towards the bottom end 130, The orientation of the embossing axis 150 changes from one embossing 140 to the next. Specifically, the orientation of the vertical lower embossing 140 is such that the corresponding embossing 14 The closer 0 is to the bottom end 130, the steeper the radial slope. , the pleats become more parallel to the folds 120 and gravity 124.

[0101] The angle of the embossing axis 150 varies from one embossing to the next. This is further illustrated in Figure 14, where two lower embossments 140A' and 140B' are The embossing axis 150' of B' is connected to the two upper embossings 140A and 140B. The embossing axis 150 is steeper than the embossing axis 150. In particular, the embossings 140B, 140B' are In the pleat panel hidden behind the pleat panel forming the embossing 140A, 140A' The formed structure is shown by the dashed line.

[0102] Furthermore, the embossment 140 in FIG. 14 is not teardrop-shaped, but rather an oval, which is an alternative shape. be.

[0103] The increasing steepness when moving towards the bottom 130 indicates that the embossing 140 is a barrier to water penetration. This increases the effect of obstructing the flow of water droplets 110 into the upstream pleats of the filter media. This prevents bacteria from entering the area, making the entire surface area available for filtration. The performance of the bottom area of the filter element 100 is better because the separated water droplets 110 This is particularly convenient when moving vertically downward toward the bottom end 130 and the drain pan 114. The increased ability to impede the progress of water is due to the downward flow of water 112. The lowermost portion of the filter element 100 has a higher water concentration before collecting water at 114. This helps to offset the fact that the resulting The angle of the embossing axis 150' is such that the lower portion of the filter media 102 impedes the progress of water. Improve performance.

[0104] In a preferred embodiment, the embossing 140A on the pleat panel 122A is When viewed perpendicularly to the panel 122A, the embossing 140B overlaps with the embossing 140B of the panel 122A. The first end of the embossing 140B is aligned with the first ends of two adjacent embossings 140A. However, the first end of the embossing 140A is positioned perpendicular to the edge of the The embossing 140B is positioned vertically between the first end 146 and the second end 148. It is preferable.

[0105] The embossing axis 1 relative to the fluid flow (e.g., generally radial) through the media 102 The 50° angle prevents the condensed droplets from being reintroduced into the medium 102. This prevents the flow of water through the separator and also uses gravity to assist in water separation.

[0106] As illustrated in FIG. 14, in one embodiment, the embossing axis 150 is aligned in the direction of fluid flow. fold 120 and gravity so that it stretches toward the top 132 when moving in the opposite direction. This orientation is due to the droplet 110 moving vertically downward due to gravity 124. , causing the water droplets 110 to move radially outward (illustrated by arrows 111). This further facilitates the removal of water from the fluid being treated. Referring to FIG. It moves outward towards the vertical wall of the wall 117. However, the opposite orientation can be implemented.

[0107] Adjacent the plurality of embossments 140A, 140B, 144, the filter media 102 includes: It has a plurality of flat surface areas 160 .

[0108] Preferably, the structural embossing 140A on one of the pleat panels 122A is 2A, 122B are folded against each other at crease 120, the embossing 140B is folded. The fold is formed so as to be axially positioned between the embossments 140A along the crease 120. 120, axially from the structural embossing 140B of the adjacent pleat panel 122B. This allows the embossing 140B to be aligned with the adjacent pleat panels 122A, 122B. 22B. This helps maintain proper spacing between panels 122A and 122B.

[0109] In a preferred embodiment, these surface regions 160 are manipulated to have increased surface roughness. More specifically, the filter media 102 is generally formed with a first surface roughness, and then The user then manipulates the filter media 102, particularly within these flat surface areas 160. This increases the surface roughness.

[0110] In one embodiment, the surface roughness of the upstream surface is equivalent to the surface roughness of 120 grit sandpaper. Preferably, the surface roughness is at least 116μ, and more preferably, equivalent to the surface roughness of 80-grit sandpaper. Preferably at least 190μ, and even more preferably at least the equivalent of 40 grit sandpaper. At least 425μ.

[0111] In one embodiment, the surface roughness 160 is at least 116μ after operation, more preferably In some preferred embodiments, the embossed surface has a surface roughness of at least 425 microns. Note that the surface roughness 140 has a height at least three times greater than the surface roughness.

[0112] In some embodiments, the surface roughness of the filter media after operation is reduced by at least 50%. , more preferably by 100%, and even more preferably by at least 400% .

[0113] In some embodiments, the surface roughness of the upstream surface 142 is greater than the surface roughness of the downstream surface 144. Typically, but not always, the surface roughness of only the upstream surface 142 is The surface is operated because it is the first surface that the dirty fluid with entrained water comes into contact with. The roughness increases the surface energy of the upstream surface 142, which in turn increases the moisture content of the upstream surface 142. It helps to improve separation ability.

[0114] In FIG. 2, the increased surface roughness is illustrated schematically by stippling on the surface of the filter media 102. This roughness is sometimes called micro-roughness.

[0115] FIG. 4 illustrates a simplified filter media processing system 200. The system typically The filter media 102 is a roll of filter media used to form the filter media. It includes a media supply 202. The filter media is unwound from a roll and then processed.

[0116] Downstream of the filter media source 202, one or more surfaces and / or or one or more media manipulation tools 205, 206 that perform surface manipulations on the area. There is a media handling station 204 including:

[0117] In certain implementations, the media handling stations 204 take the form of opposing compression rolls. In another implementation, the media handling tool is provided by a pair of opposing belts. In other implementations, the media handling tool controls the flow through the media handling station 204. A pair of lines moving toward and away from each other along an axis generally perpendicular to the medium The stamping plate is provided by a stamping plate that operates in a circular motion.

[0118] In one implementation, the media handling station 204 moves only one side of the filter media: Specifically, the side of the filter media that becomes the upstream surface 142 described above is manipulated. In an embodiment, the media manipulation tools 205, 206 associated with that side of the media may The surface roughness of the corresponding surface is manipulated to obtain a surface roughness compared to the initial surface roughness of the filter media. Increase.

[0119] Preferably, the media handling station 204 does not remove any or substantially all of the filter media. without moving either the surface or the substrate, e.g., without polishing or laser etching the media. Rather, the surface roughness is modified by simply compressing the filter media. The removal method may leave debris, among other things, on the filter media.

[0120] In one implementation, the media handling tools 205, 206 that define the desired surface roughness are It is made of a material that is stiffer than the other materials of the tools 205, 206. In the mounted configuration, the media manipulation tools 205, 206 are laser etched into the surface of the tooling. The surface roughness profile may be different.

[0121] In one embodiment, the same media manipulation tool 205 or 206 may have a structural element formed therein. In some embodiments, the media handling tool 20 has both bossing and surface roughness features. 5, 206 provides only structural embossing without any surface roughness features.

[0122] In some embodiments, the media manipulation tools 205, 206 have structural elements formed therein. The rigid member has a bossed profile, and the micro-roughness film adheres to the rigid member. A micro-roughness film surrounds the structural embossing.

[0123] In some implementations, the media handling station 204 performs one operation first. and then using a separate set of sequentially aligned tools to perform the other process. It has a two-step process to create roughness and structural embossing. Typically, the roughness process is First, again, other systems may have different media handling characteristics. It may have a

[0124] In some implementations, structural embossing manipulates the surface to increase the surface roughness. Instead of allowing the filter media to flow through the rest of the pleated panel (the substantially planar portion of the filter media), The coating is manipulated to provide improved surface roughness.

[0125] In a preferred implementation, the media manipulation tools 205, 206 are aligned to form a single structural embossment. Both raised and recessed structural embossing features form a textured surface. For example, the protrusions on the tool 205 may be aligned with and cooperate with the filter media. 6, pressing the filter media into the corresponding recesses to form the embossments. However, preferably, cooperating protruding / recessed features (e.g., cooperating convex and concave features) are While surface roughness features may be used to form structural embossing, surface roughness features are typically Rather, the surface roughness features are formed in a coordinated manner. Without any cooperating features between the tools 205 and 206 that form the surface roughness, only one tool 205 Or formed by the other tool 206.

[0126] In one implementation, the filter media is a laminate of multiple layers of filter media. and the layers of the stack are joined together before passing through the media handling station 204. Fix.

[0127] Furthermore, it is preferable to strengthen and increase the surfaces that have had surface roughness, and these surfaces It is preferred that the filter medium is not substantially coated with the surface roughness. This is especially true since it is not used as a means to fasten the separate layers together. The surface roughness remains unobstructed by other materials, so that improved water separation characteristics remain. It should be.

[0128] Downstream of the tools 205, 206, adjacent pleat panels 122 are aligned with corresponding pleat folds 12 There is a folding machine 207 that folds at 0.

[0129] FIG. 5 shows the fold lines 320 defining the pleat panels 322A, 322B, the structural embossing 340A, 340B, and manipulated to include a flat surface region 360 with enhanced roughness. 3 is a photograph of the fabricated filter media 302.

[0130] Figure 6 is a photograph similar to Figure 5. However, the filter media has a structural embossing. The surface roughness surrounding the workpiece was not enhanced.

[0131] FIG. 7 is a photograph of an unmanipulated sample of the filter media used for the arrangements of FIGS. 5 and 6. is true.

[0132] Applicants have performed various tests to verify the filter performance of all three arrangements of FIGS. The operating parameters of the media were compared. However, all samples were However, not all tests were carried out.

[0133] 8 and 9 show the results for the control filter media of FIG. 7 and the modified filter media of FIG. 5. The contact angles of water on the surfaces of the corresponding media are measured using a goniometer. It was confirmed that the samples with increased surface roughness had larger contact angles. More specifically, the control sample had an average contact angle (average of two values) of 129°±0.8°. On the other hand, the samples with increased surface roughness exhibited an average contact angle of 135°±0.6° (the difference between the two values). (average).

[0134] Figure 10 illustrates a comparison of flow restriction and flow rate based on SAE J905. The fluid is ultralow sulfur diesel (ULSD) As illustrated, the modified samples each had a lower solubility than the control sample at the same flow rate. It had a reduced pressure drop.

[0135] FIG. 11 illustrates a comparison of water separation efficiency over time as tested according to SAE J1488. The test flow rate was 1 gpm. The flow was from outside to inside using a cylindrical filter element. Ta.

[0136] Figure 12 shows the pressure drop over time for three samples tested according to SAE J1488. The test flow rate was 1 gpm. The flow was measured using a cylindrical filter element. It was inside from the inside.

[0137] All references cited herein, including publications, patent applications, and patents, are hereby incorporated by reference in their entirety. All references are individually and specifically indicated to be incorporated by reference and are not to be construed as limiting the scope of the present invention. No. 6,023,799, filed on Dec. 1, 2003, which is incorporated herein by reference to the same extent as if set forth therein.

[0138] In the context of describing the present invention (particularly in the context of the claims below), the terms "a" and "a The use of "n" and "the" and similar references refers to the Unless otherwise specified or the context clearly contradicts, the terms "singular" and "plural" should be construed as covering both the singular and the plural. The terms "comprising," "having," and "including" "including" and "containing" are used to refer to should be construed as open-ended terms (i.e., meaning "including but not limited to") unless References to values herein refer to separate values falling within a range unless otherwise specified herein. It is merely intended to serve as a shorthand way of referring to each value individually, and the separate values Each is incorporated herein as if individually set forth herein. Unless otherwise specified herein or the context clearly contradicts otherwise, Thus, all methods described herein can be performed in any suitable order. Any and all examples or representative language (e.g., "such as" The use of "") is merely intended to better elucidate the invention and is not specifically claimed. No language in this specification shall be construed as being essential to the practice of the invention. Nothing in this document should be construed as indicating any non-claimed element as an inclusion.

[0139] This specification describes preferred embodiments of the present invention and provides a method for carrying out the present invention. Variations of these preferred embodiments include those described above, including the best mode known to the inventors. The inventors believe that such a procedure may be readily apparent to a skilled artisan upon reading the description. It is anticipated that such variations may be employed and that the present invention may be practiced in ways other than those specifically described herein. Accordingly, the present invention is intended to be practiced in accordance with the principles of the present invention as permitted by applicable law. Modifications and equivalents of the subject matter recited in the claims appended hereto as Moreover, the present invention is not limited to the above unless otherwise specified herein or the context requires otherwise. Any combination of the above-described elements in all possible variations thereof is contemplated unless expressly contradicted by law. This includes.

Claims

1. A pleated filter element comprising: The filter is pleated and continuous to provide spaced upstream and downstream filter surfaces. a plurality of longitudinally extending adjacent opposing folds of selected depth and spacing between the fold sides; a filtration medium having adjacent pleat sides, the adjacent pleat sides being adjacent to a corresponding pleat side; Filtration media connected by wires Equipped with Each of the successive pleat sides comprises: a first side and a second side; and forming a first surface and a second surface on the adjacent side. and multiple structural embossings The structural embossing has i) different geometries between adjacent structural embossments on the side; ii) between adjacent embossments on the side surface relative to the longitudinal axis of the filtration media different angles of protrusions along said at least one of said first side and said second side; 、 iii) non-polygonal configurations; iv) teardrop geometry, and v) a first end and a second end, the first end and the second end extending therebetween; The embossing shaft is connected to a corresponding one of the pleat sides. a first end and a second end extending in an orientation non-parallel and non-perpendicular to the fold line; A pleated filter element having at least one of:

2. A pleated filter element comprising: a plurality of pleat sides having a first side forming an upstream surface and a second side forming a downstream surface; a pleated filter medium including a front surface and a plurality of folds, wherein adjacent pleat sides are pleated filter media connected by corresponding ones of the plurality of folds; the first and front sides of the pleat lateral surface having first and second ends, respectively; a plurality of structural embossments formed in at least one of the second sides, The first end and the second end define an embossing axis of the structural embossing. The embossing axis is non-parallel to the fold line connected to the corresponding pleat side. and multiple structural embossings extending in a non-perpendicular orientation. A pleated filter element comprising:

3. the pleated filter media forms a tube of filter media defining a central longitudinal axis; the folds extend parallel to the longitudinal central axis; Each of the structural embossments has a length along the embossing axis of the structural embossment. Long and slender, 3. The pleated filter element of claim 2.

4. a first structural embossment among the plurality of structural embossments and the plurality of structures; The second structural embossing among the structural embossings is a first embossment among the plurality of fold sides. The embossing axis of the first structural embossing is formed in the side surface of the second structural embossing. 2 or 3, which extend at an angle different from the embossing axis of the structural embossing of 2. The pleated filter element according to claim 1.

5. The pleated filter media has a gravity top and a gravity bottom, the gravity top comprising: The fold is located vertically above the gravity bottom point, and the fold is located between the gravity top point and the gravity bottom point. and the embossing axis of the first structural embossing extends along the axis of the second structural embossing. the first structural embossing is aligned less with gravity than the embossing axis of the first structural embossing; is located closer to the gravity top than the second structural embossing.

10. The pleated filter element as described above.

6. The pleated filter media comprises a block of filter media defining an upstream surface and a downstream surface. The block of filter media is configured such that fluid to be filtered passes from the upstream surface to the downstream surface. a flow direction, the flow direction being generally perpendicular to the plurality of folds; 6. The pleated filter element of claim 5.

7. The embossing axis moves in the direction of flow from the upstream surface to the downstream surface. As the embossing axis moves upward toward the gravitational top of the pleated filter media, The pleated filter element of claim 6 , wherein the pleated filter element is angled relative to the folds so as to move.

8. A third structural embossment among the plurality of structural embossments is provided on the pleat side of the plurality of structural embossments. a first fold in the plurality of folds is formed within the second fold side of the surface; formed between the first pleat side and the second pleat side, and before the third structural embossing The first end portion is formed by the first structural embossing along the first fold line. and a first end of the second structural embossing, the first end of the second structural embossing being axially positioned between the first end and the first end of the second structural embossing. The first end of the second structural embossing is adjacent to the third structural embossing. Axially positioned between the first end and the second end, the first structural embossing The second structural embossing and the third structural embossing are folded over each other.

6. The pleated filter element of claim 4, wherein the pleated filter element is oriented such that ...

9. The plurality of structural embossments each have a width generally perpendicular to the embossing axis. and wherein the width increases when moving from the first end toward the second end. The pleated filter element of any one of claims 2 to 8.

10. The first structural embossing and the second structural embossing are A protrusion is formed on the first side of the filter media and a depression is formed on the second side of the pleated filter media. Forming The third structural embossing forms a protrusion on the second side of the second pleat side, forming a recess on the first side of the second pleat side; 9. The pleated filter element of claim 8.

11. the filtration media is formed into a tube of pleated filter media defining a central longitudinal axis; Each of the structural embossments is formed on the first side and the second side of the corresponding pleat side. The protrusion is attached to one of the two sides of the first and second sides of the corresponding pleat side. forming a depression in the other of the the width of the protrusion and the depth of the depression measured generally perpendicular to the corresponding pleat side; The embossing is radially spaced from the central longitudinal axis of the tube of pleated filter media. increases when moving along the axis of the The pleated filter element of any one of claims 2 to 10.

12. The pleated filter media is formed into a tube of pleated filter media, and the pleated The tube of filter media defines the central longitudinal axis, and the tube of pleated filter media has: The fluid to be filtered flows radially through the tube of pleated filter media as it is filtered. It is configured as follows: The pleated filter media tube has a gravity top and a gravity bottom, the gravity top is vertically above the gravity bottom point, and the central longitudinal axis and the fold are The embossing of the structural embossing extends between the gravity top and the gravity bottom. The shaft moves along the embossing axis toward the gravity bottom. A machining axis is oriented relative to the longitudinal axis so as to extend radially outward and away from the longitudinal axis. will be The pleated filter element of any one of claims 2 to 11.

13. A method for making a filter element according to any one of claims 1 to 12, comprising the steps of: providing a filter media; embossing the filter media with a plurality of structural embossments; folding the filter media at a plurality of folds to form a plurality of pleated sides; A method for providing

14. 1. A method for filtering water from a fuel stream, comprising: The fuel is introduced into the filter element from an inlet of the filter element according to any one of claims 1 to 13. and forcing the fuel flow through the filter media of the filter element as it flows to the outlet of the filter element. Step A method for providing

15. 1. A filtration system comprising: a filter head having an inlet and an outlet; a housing defining a drain receiving area; 15. The filter element according to claim 1, wherein at least one of the filter elements is disposed inside the housing. A portion of the inlet and outlet are positioned vertically above the drain receiving area and are fluidly connected to the inlet and outlet. A filter element placed between the mouth and A filtration system comprising:

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