Abstract:
A filter media cartridge and method of making filter media wherein the filter media has a plurality of folds formed into a tube with an internal support core supporting the media material. A plurality of retention bands mounted about the filter media to retain the filter media in position and prevent media from expanding outwardly sufficiently to damage the filter media. At least a one glue bead located circumferentially about the filter media. The glue bead adhering adjacent folds of the media together to provide support and regular spacing of the folds so that the folds are prevented from collapsing with respect to one another.

Description:
[0001]    This application claims the benefit of U.S. Provisional Application No. 62/016,138 filed on Jun. 24, 2014. 
     
    
     BACKGROUND 
       [0002]    The present invention relates to filter media cartridges used in air filtering systems, particularly industrial air filtering systems. 
         [0003]    Air filtering systems are commonly used in numerous industrial applications. Typically, air filter systems draw air from the surrounding environment, pull that air through one or more filters and then expel the filtered air back into the surrounding environment. The filters used can have many shapes, but are typically either flat or tubular. The tubular filters typically draw air through the exterior of the filter into the interior. The filter captures contaminants that are entrained in the air and the filtered air exits the air filter system. 
         [0004]    As the filter begins to accumulate contaminants, it is necessary to clean the filter media. One method of cleaning the filter is to pulse compressed air in the interior of the tubular filter media and blow the contaminants off the media. The contaminants are then collected in a pan and discarded. 
         [0005]    One disadvantage of known filter media is the inability to withstand the drawing of air through the media to filter the air and the cleaning of the filter by pulsing compressed air through the filter media. The pressures used are high and results in undue flexing of typical filter media. After repeated flexing, the filter media can break down in numerous ways, such as for example folding upon itself, which reduces the filtration area, tearing which results in an inability to filter, etc. 
         [0006]    The present invention overcomes these disadvantages by providing a unique filter media cartridge that has reinforced pleats that withstand repeated pressure changes, a central support to withstand repeated pressure changes and support ribs to add additional overall strength to the filter media. 
         [0007]    The invention will become more apparent to those skilled in the art from the detailed description of a preferred embodiment. The drawings that accompany the detailed description are described below. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is an exploded view of the filter media cartridge of the present invention. 
           [0009]      FIG. 2  is a plan view of the filter media cartridge of the present invention. 
           [0010]      FIG. 3  is a cutaway view of the filter media cartridge of the present invention taken along line A-A of  FIG. 1 . 
           [0011]      FIG. 4  is a cutaway view of the filter media cartridge of the present invention taken along line C-C of  FIG. 1 . 
           [0012]      FIG. 5  is an enlarged section of the filter media cartridge of the present invention. 
           [0013]      FIG. 6  is a perspective view of an example of a air filtration unit incorporating filter media of the present invention. 
           [0014]      FIG. 7  is a block diagram illustrating the method of making the filter media of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0015]    With reference to  FIGS. 1 and 2 , the filter media cartridge of the present invention is shown generally at  10 . The filter cartridge  10  includes a filter media  12  mounted between a top pan  14  and a bottom pan  16 . The pans  14  and  16  hold the media in position and facilitate installation of the filter media cartridge  10  within an air filter unit. Retention bands  18  are mounted about the filter media to retain the media  12  in position. This is particularly important when compressed air is pulsed through the media  12  in a reverse direction. Without the restraint of the bands  18 , the filter media  12  would be blown outwards away from the internal support core  20  during a compressed air pulse, which can cause damage, ripping or tearing to the media  12 , allowing pollutants, particulate or dirt through the filter, compromising its filtration efficiency. In the disclosed embodiment, the bands  18  are mounted to the filter media  12  by adhesive. 
         [0016]    To provide additional support, internal support core  20  is provided. The internal support core  20  adds additional support to the filter media cartridge, extending the media&#39;s life during operation and cleaning. The internal support core  20  in the disclosed embodiment is expanded metal. As is well known to those of ordinary skill in the art, the expanded metal is formed by making numerous cuts or slits in the metal and then stretching or expanding the metal to form enlarged openings at the various cuts. The expanded metal is shown schematically at  21  in  FIG. 2 . Ribs  23  are provided along the length of the core  20  and are formed by leaving portions of the expanded metal core  20  free from cuts. The ribs  23  form a continuous spiral support along the length of the internal support core  20 . 
         [0017]    The filter media  12  of the present invention includes a glue bead  22  that provides spacing between the folds of the media  12  and reinforces the media  12 . The glue bead  22  is positioned along the interior of the media  12  adjacent the internal support core  20 . In the disclosed embodiment, the glue bead is formed in at least one strip along the internal circumference of the media  12 , and in the preferred embodiment, along the top and bottom of the media  12 . In the even more preferred embodiment, the glue bead  22  is formed at spaced locations along the length of the media  12 . The glue bead  22  is applied in a strip along the media  12  prior to the media being folded. When the media  12  is folded, the glue adheres adjacent folds together along the interior of the media  12 . 
         [0018]    The glue beads  22  provide substantial support and regular spacing to the folds of the media  12 . This prevents the folds and pleats of the media  12  from collapsing against one another when under negative pressure from the airflow being drawn through the media  12 . This means the entire surface area of the media  12  is exposed and able to be effectively utilized by the airstream passing through the filter, to evenly distribute the captured contaminants, and to reduce the level of pressure drop and resistance to the airflow created by the media  12  and the captured particulate layer, also known as the dust cake. 
         [0019]    With reference to  FIG. 7 , a block diagram representation of the method of making the filter media of the present invention is illustrated. In the preferred method of making the filter of the present invention, a flat sheet of filter material  12  is fed into a pleating machine  50 . The pleating machine creases the filter material to form the folds or pleats. In the disclosed embodiment, the creases are spaced apart at approximately 2 inch intervals along the length of the filter material. The creases create a series of peaks and valleys along the length of the filter material. These pleats or folds are approximately 2 inches deep. 
         [0020]    After being creased, the filter material exits the pleating machine and enters the glue bead machine  52 . The glue bead machine  52  has a number of spaced glue nozzles  54 . In the disclosed embodiment the glue nozzles  54  are approximately on 8 inch centers to apply multiple glue beads along the length of the creased filter material sheet  12 . As the sheet enters and progresses through the glue bead machine  52 , the filter material  12  begins to unfold allowing the glue to the applied along the peaks and valleys of the sheet. The glue bead is generally applied in a continuous strip along the length of the filter medium  12 . Depending upon the filter medium, a plurality of glue strips are spaced along the width of the filter medium and extend along the length of the filter medium. 
         [0021]    Upon exiting the glue bead machine  12 , the sheet is forced to fold at the creases. A stop bar  56  is used to stop the forward movement of the filter medium  12 , which causes the filter medium to fold as it exits the glue bead machine  52 . As the filter media  12  folds, adjoining peaks and valleys contact one another with the glue bead strip at the adjoining peaks and valleys adhere to bond the peaks and valleys together at that location. The filter medium is than allowed to cure to form a pleated sheet with peaks and valleys with the adjoining peaks glued together at spaced locations along the width of the filter medium. After curing, the sheet of filter medium is cut to a desired length and formed into a tube. The glue is flexible enough to allow the media to be formed into a tube and have the peaks fan out. 
         [0022]    In the disclosed embodiment, glue, in this application a two part curing adhesive is applied to the ends of the tube  12  and to the end caps  14  and  16 . The end caps  14  and  16  can then be secured to the ends of the tube  12 . Additionally, the core  20  is adhered to the ends caps  14  and  16  by the same adhesive. 
         [0023]    As will be appreciated by those of ordinary skill in the art, either the top pan  14  or bottom pan  16  or both have open centers to allow the filtered air to flow through the cartridge  10 . In the disclosed embodiment, the top and bottom pans  14  and  16  and the core  20  are attached to the media  12  by the two part adhesive. 
         [0024]    With reference to  FIG. 6 , an example of an air filtration unit is generally illustrated at  30 . The air filtration unit has a housing  32 . The filter media cartridges  10  of the present invention are mounted in the housing  32 . A fan  34  and motor  36  draw air through an intake  38 . The air that is drawn in is pulled through the filter media cartridges  10 . The air has entrained particulates that are trapped in the filter media cartridge  10 . The air that is pulled through the media  12  then is expelled to through the outlet  40 . 
         [0025]    Valves and nozzles can be used to pulse compressed air in reverse through the filter media cartridges  10  to blow off the particulates that have been trapped in the filter media  12 . The particulate that is blown off the media  12  is deposited in the container  42 . The container  42  can then be emptied. 
         [0026]    The foregoing invention has been described in accordance with the relevant legal standards, thus the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and do come within the scope of the invention. Accordingly, the scope of legal protection afforded this invention can only be determined by studying the following claims.