Patent Description:
The control of pleat spacing in filter assemblies is valuable for providing structural support to the filter and to provide performance enhancement to the life of the filter. Conventional filter assemblies incorporate one or more end caps that are generally annular shaped structures having a flat bottomed well that is disposed about a central aperture. To create a filter assembly with a pleated filter media, a significant amount of a curable resin is added to the flat-bottomed end cap and the pleated filter media is inserted and secured to the end cap during the curing process. If the cured resin fails, such as due to improper installation, there is nothing to keep the pleats of the pleated filter media from blinding under strain.

The pleats of the filter media prepared in a flat-bottomed end cap often suffer from pleat blinding caused by excessive strain during the filtration process, particularly related to high pressure within a system and to the high viscosity of the fluid being filtered. Thus, there exists a need to provide structural integrity to the pleats of a pleated filter medium to prevent pleat blinding and filtration inefficiencies.

<CIT> relates to a structure of filtering bag combination comprising a filtering member with multiple folds to cover a support having a plurality of bracing members.

<CIT>shows a cylindrical filter cartridge having a pleated media and an external support.

<CIT> relates to a filter housing and a pleated filter for the filtration of particulate matter from fluids, particularly air. The filter has a zigzag pleated filter media and a filter frame.

<CIT> relates to a gas filter cartridge comprising a pleated filter medium and a support for use in filter systems designed to remove solid particles or dust from large volumes of gases, including air.

<CIT> relates to filters for gas or air filtration and comprising a filter membrane and support means.

<CIT> relates to an internal support composed together of fin-forming elements which support pleated media during filtering of fluids.

The invention provides a filter assembly component as claimed in claim <NUM>.

In an embodiment, a filter assembly component is included having an end cap. The end cap can include a pleat guide channel disposed about a circumference of the end cap, the pleat guide channel can have a repeating pattern that includes a plurality of peaks and a plurality of valleys distributed about the circumference of the end cap, where the pleat guide channel is configured to receive and mechanically support a pleated filter media within the pleat guide channel.

In a first aspect, a filter assembly component has a pleat guide including a repeating pattern. The repeating pattern includes a plurality of peaks and a plurality of valleys distributed about a circumference of the pleat guide, and the plurality of peaks and the plurality of valleys are configured to interface with a pleated filter media to maintain pleat spacing between corresponding pleats of the pleated filter media.

In a second aspect, in addition to one or more of the preceding or following aspects, or in the alternative to some aspects, the pleat guide includes an interior pleat guide.

In a third aspect, in addition to one or more of the preceding or following aspects, or in the alternative to some aspects, the pleat guide includes an exterior pleat guide.

In a fourth aspect, in addition to one or more of the preceding or following aspects, or in the alternative to some aspects, the plurality of peaks extend away from a center point of the pleat guide from <NUM> (<NUM> inches) to <NUM> (<NUM> inches).

In a fifth aspect, in addition to one or more of the preceding or following aspects, or in the alternative to some aspects, the pleat guide can be from <NUM> to <NUM> thick.

In a sixth aspect, in addition to one or more of the preceding or following aspects, or in the alternative to some aspects, the pleat guide includes a diameter of from <NUM> (<NUM> inches) to <NUM> (<NUM> inches) in diameter.

The pleat guide includes a central aperture.

The pleat guide defines a plurality of hollow passages extending from a central portion of the pleat guide to a circumferential surface of the pleat guide, wherein the pleat guide further defines a fluid inlet port in fluid communication with the plurality of hollow passages.

In a ninth aspect, in addition to one or more of the preceding or following aspects, or in the alternative to some aspects, the pleat guide further includes a first spoke wheel, a second spoke wheel spaced apart axially from the first spoke wheel, and a central longitudinal axle portion connecting the first spoke wheel and the second spoke wheel.

In a tenth aspect, in addition to one or more of the preceding or following aspects, or in the alternative to some aspects, the pleat guide includes: a first axial frame configured to be disposed about an exterior of the pleated filter media, a second axial frame configured to be disposed about the exterior of the pleated filter media, the second axial frame spaced apart axially from the first axial frame, and a plurality of longitudinal rods extending between valleys on the first axial frame and valleys on the second axial frame to maintain axial spacing of the first axial frame and the second axial frame.

In an eleventh aspect, in addition to one or more of the preceding or following aspects, or in the alternative to some aspects, the pleat guide includes an interior wire frame. The interior wire frame can include: a first axial frame configured to be disposed within an interior of the pleated filter media, a second axial frame configured to be disposed within the interior of the pleated filter media, the second axial frame spaced apart axially from the first axial frame, and a plurality of longitudinal rods extending between peaks on the first axial frame and peaks on the second axial frame to maintain axial spacing of the first axial frame and the second axial frame.

In a twelfth aspect, in addition to one or more of the preceding or following aspects, a filter assembly component can include an end cap and the end cap can include a pleat guide channel disposed about a circumference of the end cap. The pleat guide channel can include a repeating pattern which can include a plurality of peaks and a plurality of valleys distributed about the circumference of the end cap, and wherein the pleat guide channel can be configured to receive and mechanically support a pleated filter media within the pleat guide channel.

In a thirteenth aspect, in addition to one or more of the preceding or following aspects, or in the alternative to some aspects, the pleat guide channel includes a uniform pleat channel depth.

In a fourteenth aspect, in addition to one or more of the preceding or following aspects, or in the alternative to some aspects, the pleat guide channel includes a non-uniform pleat channel depth.

In a fifteenth aspect, in addition to one or more of the preceding or following aspects, or in the alternative to some aspects, the pleat guide channel includes a depth of from <NUM> (<NUM> inches) to <NUM> (<NUM> inches).

In a sixteenth aspect, in addition to one or more of the preceding or following aspects, or in the alternative to some aspects, the pleat guide channel includes a thickness that can be from <NUM>% to <NUM>% greater than the thickness of a pleated filter media to be placed into the pleat guide channel.

In a seventeenth aspect, in addition to one or more of the preceding or following aspects, or in the alternative to some aspects, the pleat guide channel includes a thickness that can be <NUM>% greater than the thickness of a pleated filter media to be placed into the pleat guide channel.

In an eighteenth aspect, in addition to one or more of the preceding or following aspects, or in the alternative to some aspects, the end cap includes a diameter of from <NUM> (<NUM> inches) to <NUM> (<NUM> inches) in diameter.

In a nineteenth aspect, in addition to one or more of the preceding or following aspects, or in the alternative to some aspects, the repeating pattern includes a repeating pattern of uniformly distributed peaks and valleys about the circumference of the end cap.

In a twentieth aspect, in addition to one or more of the preceding or following aspects, or in the alternative to some aspects, the repeating pattern includes a repeating pattern of non-uniformly distributed peaks and valleys about the circumference of the end cap.

This summary is an overview of some of the teachings of the present application and is not intended to be an exclusive or exhaustive treatment of the present subject matter. Further details are found in the detailed description and appended claims. Other aspects will be apparent to persons skilled in the art upon reading and understanding the following detailed description and viewing the drawings that form a part thereof, each of which is not to be taken in a limiting sense. The scope herein is defined by the appended claims and their legal equivalents.

While embodiments are susceptible to various modifications and alternative forms, specifics thereof have been shown by way of example and drawings and will be described in detail.

Pleat spacing within a pleated filter media of a filter assembly is important to the efficient and effective filtration of various fluids, including, but not to be limited to air, water, oils, fuels, hydraulics, and any high viscosity fluids. During manufacture, use, or storage, pleats can become too close together so that they can stick to one another and cause pleat blinding as fluid flows past the filter media and/or when the filter assembly is under pressure. A negative effect of close pleat spacing is that it effectively blinds significant surfaces in the filter media and reduces the overall filter surface area available for filtration. The decrease in filtration surface area can resulting in an increase in a pressure drop across a filter media and a decrease in loading on the filter media. Pleat blinding can significantly affect performance and life of a filter assembly.

Various structures as described herein can be implemented in a filter assembly in order to control pleat spacing so as to prevent pleat blinding, and to maximize overall filter performance. These structures can include components such as end caps configured with pleat guide channels and pleat guides configured to be placed along a length of a filter assembly either on an interior or exterior surface, or both, of a pleated filter media. In some embodiments, the structures described herein can be placed along targeted locations along the inside or outside of a pleated filter media.

Referring now to <FIG>, a schematic perspective view of a filter assembly <NUM> is shown in accordance with various embodiments herein. Filter assembly <NUM> includes a first end <NUM> and a second end <NUM>. The filter assembly <NUM> includes a first end cap <NUM> disposed at the first end <NUM> and a second end cap <NUM> disposed at the second end <NUM>. Disposed between the first end cap <NUM> and the second end cap <NUM> is a pleated filter media <NUM>, where pleated filter media <NUM> includes a plurality of repeating pleats about a circumference of the pleated filter media. Filter assembly can further include a sealable mounting element <NUM> at a first end <NUM>, a second end <NUM>, or both the first and second ends. Sealable mounting element can include a sealing mechanism such as, but not to be limited to an O-ring seal, threaded surface, and the like, for preventing leakage of a fluid therethrough when installed during use. The filter assembly <NUM> can further include a central aperture <NUM> defined by the filter assembly <NUM> and open at the first end <NUM> and/or the second end <NUM>. While the filter assembly <NUM> is shown as a cylindrical shape, it will be appreciated that other shapes are suitable for the embodiments described herein.

The end caps of the filter assembly can include a pleat guide channel configured to receive and mechanically support a pleated filter media within the pleat guide channel. Referring now to <FIG>, a schematic perspective view and <FIG>, a schematic top plan view, of an exemplary end cap is shown in accordance with various embodiments herein. By way of example, the second end cap <NUM> of <FIG> is represented in <FIG>. Second end cap <NUM> includes a pleat guide channel <NUM> defined by the bulk material of the end cap and having a repeating pattern about the circumference of the end cap. The repeating pattern can include a pattern that has the same shape as a given pleated filter media to be inserted into the pleat guide channel.

The filter media suitable for use with the pleat guides herein can have a plurality of pleats ranging from <NUM> to <NUM> pleats per filter media unit. In some embodiments, the number of pleats per filter media unit can be greater than or equal to <NUM> pleats, <NUM> pleats, <NUM> pleats, <NUM> pleats, <NUM> pleats, <NUM> pleats, <NUM> pleats, or <NUM> pleats, or can be an amount falling within a range between any of the foregoing. The length of the pleats for filter media suitable for use herein can include those having a length extending radially from a center point of the filter unit can be from <NUM> (<NUM> inches) to <NUM> (<NUM> inches). In some embodiments, the length of the pleats can be greater than or equal to <NUM> (<NUM> in. ), <NUM> (<NUM> in. ), <NUM> (<NUM> in. ), <NUM> (<NUM> in. ), <NUM> (<NUM> in. ), <NUM> (<NUM> in. ), <NUM> (<NUM> in. ), <NUM> (<NUM> in. ), <NUM> (<NUM> in. ), <NUM> (<NUM> in. ), <NUM> (<NUM> in. ), or <NUM> (<NUM> in. ), or can be an amount falling within a range between any of the foregoing.

The pleat guide channel <NUM> can include a repeating pattern of peaks and valleys distributed about a circumference of an end cap. By way of example, an inner circumference <NUM> of the pleat guide channel <NUM> can include a first inner perimeter peak <NUM> extending away from a longitudinal axis of the end cap, and a first inner perimeter valley <NUM> extending toward a longitudinal axis of the end cap. The outer circumference <NUM> of the pleat guide channel <NUM> can include a first outer perimeter peak <NUM> extending toward a longitudinal axis of the end cap, and a first outer perimeter valley <NUM> extending away from a longitudinal axis of the end cap.

While only a first inner perimeter peak, a first inner perimeter valley, a first outer perimeter peak, and a first outer perimeter valley are described, it will be appreciated that the pleat guide channel includes a plurality of inner perimeter peaks, inner perimeter valleys, outer perimeter peaks, and outer perimeter valleys The inner perimeter peaks of the inner circumference can be configured to align with the outer perimeter valleys of the outer circumference, and the outer perimeter peaks of the outer circumference can be configured to align with the inner perimeter valleys of the inner circumference. It will be appreciated that this configuration of peaks and valleys provides that the inner circumference and the outer circumference of the pleat guide channel can assume the same profile as each other.

It will be appreciated that while the repeating pattern of peaks and valleys in <FIG> are shown as sharp, angular structures, the shape of these peaks and valleys can also include a rounded shape, a square shape, a trapezoidal shape, combinations thereof, and the like. In some embodiments, the repeating pattern can include a repeating pattern of uniformly distributed peaks and valleys about a circumference of an end cap. In other embodiments, the repeating pattern can include a repeating pattern of non-uniformly distributed peaks and valleys about a circumference of an end cap.

Pleat guide channel <NUM> can be configured to receive a curable resin (not shown), such as a polyurethane resin, to act as a glue to affix a pleated filter media within the pleat guide channel of an end cap. In various embodiments, the bottom of the pleat guide channel can be flat, while in other embodiments the bottom of the pleat guide channel can be rounded, triangular, and the like.

In various embodiments, the pleat guide channel can include a uniform pattern about the circumference of the end cap. In other embodiments, the pleat guide channel can include a non-uniform pattern about the circumference of the end cap. In some embodiments the end cap includes only one pleat guide channel, while in other embodiments the end can include more than one pleat guide channel. In other embodiments, the pleat guide channel can include be included to accommodate a pleated filter media that includes a variable pleat height design.

The depth of the pleat guide channel can include depths of from <NUM> (<NUM> inches) to from <NUM> (<NUM> inches). In various embodiments, the depth of the pleat guide channel can include depths of from <NUM> (<NUM> inches) to <NUM> (<NUM> inches). In some embodiments, the pleat guide channel can include those having depths of from <NUM> (<NUM> inches), <NUM> (<NUM> inches), <NUM> (<NUM> inches), <NUM> (<NUM> inches). <NUM> (<NUM> inches), <NUM> (<NUM> inches), <NUM> (<NUM> inches), and <NUM> (<NUM> inches), or any depth falling within a range wherein any of the forgoing depths can serve as the lower or upper bound of the range, provided that the lower bound of the range is a value less than the upper bound of the range. In some embodiments, the pleat guide channel comprises a uniform pleat channel depth. In other embodiments, the pleat guide channel comprises a non-uniform pleat channel depth.

The width of the pleat guide channel can include widths of from about <NUM>% to <NUM>% greater than the width of a pleated filter media to be placed into the pleat guide channel. In some embodiments, the width of the pleat guide channel can include those having a width of from <NUM>% to <NUM>% greater than the width of a pleated filter media to be placed into the pleat guide channel. In various embodiments, the width of the pleat guide channel can be from <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, or <NUM>% greater than the width of a pleated filter media to be placed into the pleat guide channel, or any percentage falling within a range wherein any of the forgoing percentages can serve as the lower or upper bound of the range, provided that the lower bound of the range is a value less than the upper bound of the range.

The diameter of the end cap can include those from <NUM> (<NUM> inches) to <NUM> (<NUM> inches) in diameter. In various embodiments, the diameter of the end cap can include those from <NUM> (<NUM> inches) to <NUM> (<NUM> inches) in diameter. In various embodiments, the diameter of the end cap can include an end cap with a diameter of <NUM> inches. In various embodiments, the diameter of the end cap can include an end cap with a diameter of <NUM> (<NUM> inches). In various embodiments, the diameter of the end cap can include an end cap with a diameter of <NUM> (<NUM> inches). In various embodiments, the diameter of the end cap can include those having a diameter of <NUM> (<NUM> inch), <NUM> (<NUM> inches), <NUM> (<NUM> inches), <NUM> (<NUM> inches), <NUM> (<NUM> inches), <NUM> (<NUM> inches), <NUM> (<NUM> inches), <NUM> (<NUM> inches), <NUM> (<NUM> inches), or <NUM> (<NUM> inches), or any diameter falling within a range wherein any of the forgoing diameters can serve as the lower or upper bound of the range, provided that the lower bound of the range is a value less than the upper bound of the range. In some embodiments, the diameter of the end cap can include those having a diameter of greater than <NUM> (<NUM> inches).

While the embodiments herein describe an end cap configured to receive a single pleat of a pleated filter media within each peak and valley, it will be appreciated that in some embodiments, the peaks and valleys can include configurations where each peak and valley can accept more than one pleat of a pleated filter media. In various embodiments, a single peak or valley disposed along the inner or outer perimeter can accept <NUM>, <NUM>, or <NUM> pleats from a pleated filter media, or various combinations thereof. In other embodiments, each single peak or valley can accept more than <NUM> pleats, such that the stability of the pleats is maintained. In yet other embodiments, it will be appreciated that some of the peaks and valleys described in reference to the end caps will be skipped such that they do not include a pleat from a pleated filter media.

Various types of interior pleat guides are also contemplated herein to provide mechanical support for and to control spacing between the pleats of a pleated filter media. Referring now to <FIG>, a schematic top plan view and a schematic perspective view, respectively, of an interior pleat guide <NUM> is shown in accordance with various embodiments herein. The interior pleat guide <NUM> can include a repeating pattern of peaks and valleys distributed about the outer circumference <NUM> of the interior pleat guide <NUM>. The outer circumference <NUM> can include a first guide peak <NUM> extending away from a center point of the interior pleat guide <NUM>, and a first guide valley <NUM> extending toward a center point of the interior pleat guide <NUM>. The guide peaks along the outer circumference of the interior pleat guide <NUM> can be configured to align with the filter media valleys of a corresponding pleated filter media, and the guide valleys along the outer circumference of the interior pleat guide <NUM> can be configured to align with the filter media peaks of a corresponding pleated filter media, thus providing spacing between the pleats of the filter media to keep the pleats apart from each other. Such a configuration prevents blinding of various surfaces of the pleated media filter.

It will be appreciated that while the guide peaks and valleys in <FIG> are shown as sharp, angular structures, the shape of these peaks and valleys can also include a rounded shape, a square shape, a trapezoidal shape, and the like. The interior pleat guide <NUM> of <FIG> further includes a center aperture <NUM> defined by an interior circumference of the interior pleat guide. The center aperture <NUM> can accommodate the flow of a fluid therethrough. The center aperture can also accommodate a central core supporting structure threaded therethrough. Additional configurations for the interior pleat guides will be discussed in more detail in reference to <FIG> below.

The interior pleat guide discussed in reference to <FIG> can be placed within an interior of a pleated filter media to provide structural support to the pleats of a pleated filter media to keep them separated during manufacture, storage, and operation. Referring now to <FIG>, a schematic top plan view an interior pleat guide <NUM> placed in structural contact with an interior surface of a pleated filter media <NUM> is shown in accordance with various embodiments herein. It will be appreciated that the guide peaks <NUM> of the outer circumference of the interior pleat guide <NUM> can be configured to align with the filter media valleys of an inner circumference of a pleated filter media <NUM>, and the guide valleys <NUM> of the outer circumference of the interior pleat guide <NUM> can be configured to align with the filter media peaks <NUM> of the inner circumference of the pleated filter media <NUM>. The alignment of peaks and valleys allows the peaks and valleys on the interior pleat guide to interface with the pleated filter media to maintain pleat spacing between corresponding pleats of the pleated filter media. Thus, spacing control can be maintained between the pleats of the filter media to keep the pleats apart from each other during manufacture, storage, and operation.

It will be appreciated that not every pleat of a pleated filter media needs a peak or valley of the pleat guide to be in supportive contact therewith. While the embodiments herein describe an interior pleat guide configured to include peaks and valleys that each support a single pleat of a pleated filter media, it will be appreciated that in some embodiments, the interior pleat guide can include spacing regions between neighboring peaks and valleys that are equivalent to the width of a pleat of a pleated filter media but do not provide supportive contact thereto. As such, the interior pleat guides herein can be configured to skip every nth pleat of a pleated filter media, where n can be <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or more.

One or more interior pleat guides can be placed along an interior length of a pleated filter media to provide structural support to the pleats to keep them separated during manufacture, storage and operation. Referring now to <FIG>, a schematic side plan view shows two interior pleat guides <NUM> placed in structural contact within an interior of a pleated filter media <NUM> is shown in accordance with various embodiments herein. The filter assembly <NUM> includes a first end <NUM> and a second end <NUM>, including a first end cap <NUM> disposed at the first end <NUM> and a second end cap <NUM> disposed at the second end <NUM>. Disposed between the first end cap <NUM> and the second end cap <NUM> is a pleated filter media <NUM>, where pleated filter media <NUM> includes a plurality of repeating pleats about a circumference of the pleated filter media. Filter assembly <NUM> further includes a sealable mounting element <NUM> at the first end <NUM>.

Filter assembly <NUM> includes two interior pleat guides <NUM> disposed along the length of the pleated filter media <NUM>. While only two interior pleat guides are shown in <FIG>, it will be appreciated that one or more interior pleat guides can be included in the filter assemblies as contemplated herein. In some embodiments, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> interior pleat guides can be included along a length of the pleated filter media of the filter assembly. In some embodiments, the filter assemblies described herein can include any number of interior pleat guides falling within a range wherein any of the forgoing numbers of interior pleat guides can serve as the lower or upper bound of the range, provided that the lower bound of the range is a value less than the upper bound of the range. In various embodiments, one or more interior pleat guides can be connected with struts or other connection means along a length of a pleated filter media to create a cage-like configuration of interior pleat guides. Any number of the interior pleat guides can be attached to the pleated filter media using a glue, heat, or other method of fixation.

Various types of exterior pleat guides are also contemplated herein to provide mechanical support for and to control spacing between the pleats of a pleated filter media. Referring now to <FIG>, a schematic top plan view of an exterior pleat guide <NUM> is shown in accordance with various embodiments herein. The exterior pleat guide <NUM> can include a repeating pattern of peaks and valleys distributed about the inner circumference <NUM> of the exterior pleat guide <NUM>. The inner circumference <NUM> can include a first guide peak <NUM> extending toward a center point of the exterior pleat guide <NUM>, and a first guide valley <NUM> extending away from a center point of the exterior pleat guide <NUM>. The guide peaks along the inner circumference of the exterior pleat guide <NUM> can be configured to align with the filter media valleys of a corresponding pleated filter media, and the guide valleys along the inner circumference of the exterior pleat guide <NUM> can be configured to align with the filter media peaks of a corresponding pleated filter media, thus providing spacing between the pleats of the filter media to keep the pleats apart from each other during manufacture, storage and operation. Such a configuration prevents blinding of various surfaces of the pleated media filter.

It will be appreciated that while the peaks and valleys in <FIG> are shown as sharp, angular structures, the shape of these peaks and valleys can also include a rounded shape, a square shape, a trapezoidal shape, and the like. The exterior pleat guide <NUM> of <FIG> includes a center aperture <NUM> defined by an interior circumference of the interior pleat guide. The center aperture <NUM> can accommodate the filter media therethrough.

The exterior pleat guide discussed in reference to <FIG> can be placed around the exterior of a pleated filter media to provide structural support to the pleats keep them separated during manufacture, storage and operation. Referring now to <FIG>, a schematic top plan view of an exterior pleat guide <NUM> placed in structural contact with the exterior surface of a pleated filter media <NUM> is shown in accordance with various embodiments herein. It will be appreciated that the guide peaks <NUM> along the outer circumference of the exterior pleat guide <NUM> can be configured to align with the filter media valleys <NUM> of an outer circumference of a pleated filter media <NUM>, and the guide valleys <NUM> along the outer circumference of the exterior pleat guide <NUM> can be configured to align with the filter media peaks <NUM> of the outer circumference of the pleated filter media <NUM>. The alignment of peaks and valleys allows the peaks and valleys on the exterior pleat guide to interface with the pleated filter media to maintain pleat spacing between corresponding pleats of the pleated filter media. Thus, spacing control can be maintained between the pleats of the filter media to keep the pleats apart from each other during manufacture, storage, and operation.

As described above with respect to the interior pleat guides, an exterior pleat guide need not be configured to include peaks and valleys that each support a single pleat of a pleated filter media. It will be appreciated that in some embodiments, the exterior pleat guide can include spacing regions between neighboring peaks and valleys that are equivalent to the width of a pleat of a pleated filter media but do not provide supportive contact thereto. As such, the exterior pleat guides herein can be configured to skip every nth pleat of a pleated filter media, where n can be <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or more.

One or more exterior pleat guides can be placed along an exterior length of a pleated filter media to provide structural support to the pleats to keep them separated during manufacture, storage, and operation. Referring now to <FIG>, a schematic side plan view of two exterior pleat guides <NUM> placed in structural contact within an exterior of a pleated filter media <NUM> is shown in accordance with various embodiments herein. The filter assembly <NUM> includes a first end <NUM> and a second end <NUM>, including a first end cap <NUM> disposed at the first end <NUM> and a second end cap <NUM> disposed at the second end <NUM>. Disposed between the first end cap <NUM> and the second end cap <NUM> is a pleated filter media <NUM>, where pleated filter media <NUM> includes a plurality of repeating pleats about a circumference of the pleated filter media. Filter assembly <NUM> further includes a sealable mounting element <NUM> at the first end <NUM>.

Filter assembly <NUM> includes two exterior pleat guides <NUM> disposed along the length of the pleated filter media <NUM>. While only two exterior pleat guides are shown in <FIG>, it will be appreciated that one or more exterior pleat guides can be included in the filter assemblies as contemplated herein. In some embodiments, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> exterior pleat guides can be included along a length of the pleated filter media of the filter assembly. In some embodiments, the filter assemblies described herein can include any number of exterior pleat guides falling within a range wherein any of the forgoing numbers of exterior pleat guides can serve as the lower or upper bound of the range, provided that the lower bound of the range is a value less than the upper bound of the range.

In various embodiments, one or more exterior pleat guides can be connected with struts or other connection means along a length of a pleated filter media to create a cage-like configuration of exterior pleat guides. Any number of the exterior pleat guides can be attached to the pleated filter media using a glue, heat, or other method of fixation.

It will be appreciated that the filter assemblies as described herein can utilize any combination of the end caps having pleat guide channels disposed therein, the interior pleat guides, and the exterior pleat guides, as described herein.

Both interior pleat guides and exterior pleat guides described herein can include those having guide peaks and guide valleys of varying depths. In some embodiments, the guide peaks can include those that have a length of from <NUM> (<NUM> inches) to <NUM> (<NUM> inches). In some embodiments, the guide peaks can include those that have a length from <NUM> (<NUM> inches) to <NUM> (<NUM> inches). In some embodiments, the guide peaks can include those that have a length of <NUM> (<NUM> inches), <NUM> (<NUM> inches), <NUM> (<NUM> inches), <NUM> (<NUM> inches). <NUM> (<NUM> inches), <NUM> (<NUM> inches), <NUM> (<NUM> inches), and <NUM> (<NUM> inches), or any length falling within a range wherein any of the forgoing lengths can serve as the lower or upper bound of the range, provided that the lower bound of the range is a value less than the upper bound of the range.

In some embodiments, the guide valleys can include those that have a depth of from <NUM> (<NUM> inches) to <NUM> (<NUM> inches). In some embodiments, the guide valleys can include those that have depths from <NUM> (<NUM> inches) to <NUM> (<NUM> inches). In some embodiments, the guide valleys can include those that have depth of <NUM> (<NUM> inches), <NUM> (<NUM> inches), <NUM> (<NUM> inches), <NUM> (<NUM> inches). <NUM> (<NUM> inches), <NUM> (<NUM> inches), <NUM> (<NUM> inches), and <NUM> (<NUM> inches), or any depths falling within a range wherein any of the forgoing depths can serve as the lower or upper bound of the range, provided that the lower bound of the range is a value less than the upper bound of the range.

The thickness of both interior pleat guides and exterior pleat guides described herein can include those that have a thickness of from <NUM> millimeter (mm) to <NUM>. In some embodiments, the thickness of the pleat guides herein can include those having a thickness of from <NUM> to <NUM> thick. In some embodiments, the thickness of the pleat guides herein can include those having a thickness of <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>, or any thickness falling within a range wherein any of the forgoing thicknesses can serve as the lower or upper bound of the range, provided that the lower bound of the range is a value less than the upper bound of the range. In some embodiments, the thickness of the end cap can include those having a diameter of greater than <NUM> (<NUM> inches).

The interior pleat guides can further include various configurations as discussed in reference to <FIG>. Referring now to <FIG>, schematic top plan views of various pleat guides are shown in accordance with various embodiments herein. The interior pleat guide <NUM> shown in <FIG> does not include a central aperture. Interior pleat guide <NUM> can be formed from a material that includes a honeycomb pattern of pores ranging in size such that the porous interior pleat guide can allow for the passage of a fluid therethrough. The interior pleat guide <NUM> shown in <FIG> includes a square-shaped central aperture <NUM> defined by an inner circumference of the interior pleat guide <NUM>. The interior pleat guide <NUM> shown in <FIG> includes a central aperture having four aperture portions <NUM>, <NUM>, <NUM>, and <NUM> that are each defined by the body of the interior pleat guide <NUM>. While the central apertures of <FIG> are shown to include a square shape or four pie-slice shapes, it will be appreciated that any shape can be utilized to provide a central passageway for the passage of a fluid or other filter assembly component, such as a core structure. Many of these shapes, especially those with multiple aperture portions, also include struts and supports that enhance the structural integrity of the pleat guide.

The interior pleat guides herein further include a plurality of hollow passages disposed within a thickness of the interior pleat guide as part of a back-pulsing assembly. Referring now to <FIG>, a schematic perspective view of a pleat guide back-pulsing assembly <NUM> is shown in accordance with various embodiments herein. In various embodiments, the interior pleat guides <NUM> can define a plurality of hollow passages <NUM> disposed therein. The hollow passages <NUM> extend in a radial direction from a central portion of the interior pleat guide to an outermost circumferential surface of the interior pleat guide. In various embodiments the cross section of the hollow passages can be in the shape of a circle, an oval, a square, a triangle, or an amorphous shape.

Each hollow passage <NUM> connects a central aperture <NUM> at a central portion of the interior pleat guide to an outer circumferential aperture <NUM> at the outermost circumferential surface of the interior pleat guide. It will be appreciated that while only five exemplary central apertures <NUM> are indicated in each pleat guide of <FIG>, each hollow passage <NUM> will connect a central aperture to an outer circumferential aperture <NUM>. It will be appreciated that while the outer circumferential apertures <NUM> are depicted in <FIG> as being disposed at the guide peaks <NUM>, outer circumferential apertures <NUM> can also be disposed at the guide valleys <NUM>.

The plurality of central apertures <NUM> can be connected to a hollow central coupling ring <NUM> disposed at the center of each of the interior pleat guides <NUM>. The hollow central coupling ring <NUM> can be an integral component of the interior pleat guide <NUM> or it can be a separate component to the interior pleat guides <NUM>. Each central coupling ring <NUM> can be connected by a longitudinal hollow tube <NUM>. Longitudinal hollow tube <NUM> can be further coupled to a compressed air inlet port <NUM>. The interior pleat guides <NUM> with hollow passages <NUM>, the hollow central coupling ring <NUM>, the longitudinal hollow tube <NUM>, and the compressed air inlet port <NUM> can form back-pulsing assembly <NUM>. Like other pleat guides described elsewhere herein, the back-pulsing assembly <NUM> can be placed within an interior of a pleated filter media to provide structural support to the pleats of a pleated filter media to keep them separated during manufacture, storage, and operation. While the back-pulsing assembly <NUM> shown in <FIG> only includes two pleat guides <NUM>, it will be appreciated that more than two pleat guides can be used in the back-pulsing assembly <NUM>. In some embodiments, the number of pleat guides used in the back-pulsing assembly <NUM> can be greater than or equal to two, three, four, five, six, or seven pleat guides.

The plurality of hollow passages <NUM> can have a diameter of from <NUM> millimeter (mm) to <NUM> to span a significant portion of the thickness of the pleat guides. In some embodiments, the diameter of the hollow passages herein can include those having a diameter of from <NUM> to <NUM> thick. In some embodiments, the diameter of the hollow passages described herein can include those having a diameter of <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>, or any diameter falling within a range wherein any of the forgoing diameter can serve as the lower or upper bound of the range, provided that the lower bound of the range is a value less than the upper bound of the range. In some embodiments, the diameter of the hollow passages can include those having a diameter of greater than <NUM>.

The plurality of hollow passages <NUM> can be disposed throughout a volume of the interior pleat guides so that at least <NUM> % of the volume of the pleat guides is made up of hollow passages <NUM>. In some embodiments, the volume can be greater than or equal to <NUM> %, <NUM> %, <NUM> %, <NUM> %, <NUM> %, or <NUM> %, or can be an amount falling within a range between any of the foregoing.

It will be appreciated that the hollow passages <NUM>, hollow central coupling ring <NUM>, longitudinal hollow tube <NUM> and compressed air inlet port <NUM> can be in fluid communication with one another. Each of the hollow passages <NUM>, hollow central coupling ring <NUM>, longitudinal hollow tube <NUM> and compressed air inlet port <NUM> can be directly or indirectly coupled to one another. By way of example, the components of the hollow passages <NUM>, hollow central coupling ring <NUM>, longitudinal hollow tube <NUM> and compressed air inlet port <NUM> can be of unitary construction, or they can be connected by adhesive, threads, welding, and the like.

Compressed air inlet port <NUM> can be connected to a compressed air source, where the compressed air can be pulsed through the back-pulsing assembly <NUM> so as to clear any debris from the filter medium in that has built up during use.

In various embodiments herein the pleat guides can include those having various scaffold configurations and can be placed within an interior volume of or around an exterior of a pleated filter media to provide structural support to the pleats of a pleated filter media to keep them separated during manufacture, storage, and operation. Referring now to <FIG>, schematic perspective views of various pleat guides having a scaffold configuration are shown in accordance with various embodiments herein.

The scaffold pleat guide <NUM> shown in <FIG> can include a central longitudinal axle portion <NUM>. Central longitudinal axle portion <NUM> can be connected to one or more spoke wheels <NUM>. A first spoke wheel <NUM> is spaced apart axially from a second spoke wheel <NUM>. The central longitudinal axle portion <NUM> connects the first spoke wheel to the second spoke wheel and maintains the axial spacing between the two spoke wheels. Each spoke wheel <NUM> can include a plurality of spokes <NUM> extending in a radial direction outward from the central longitudinal axle portion <NUM>. The spoke wheels <NUM> can include a plurality of spokes <NUM> such that there is one spoke <NUM> per pleat in the filter medium it is configured to support. It will be appreciated that in some embodiments, the spoke wheels <NUM> can include a plurality of spokes <NUM> such that it can be configured to skip or support every nth pleat of a pleated filter media, where n can be <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or more.

The individual spokes <NUM> can assume many configurations, including having a blunt end, a round end, and an end having a shape complementary to the shape of the filter media, and the like. In various embodiments, multiple spoke wheels <NUM> are included along the longitudinal axis of central axle portion <NUM>. The scaffold pleat guide <NUM> can be of unitary construction or can be individual components assembled together. In some embodiments, the number of spoke wheels <NUM> used can be greater than or equal to two, three, four, five, six, seven, or eight spoke wheels.

Scaffold pleat guide <NUM> is shown in <FIG> as a stand-alone structure not connected to any other components. In various embodiments, scaffold pleat guide <NUM> can be incorporated as an integral unit with the first end cap <NUM> and second end cap <NUM>, as shown in <FIG>. The scaffold pleat guide <NUM> can be a single unitary component with the first end cap <NUM> and the second end cap <NUM>, or it can be a separate component configured to connect to the first end cap <NUM> and the second end cap <NUM>.

The scaffold pleat guide <NUM> shown in <FIG> includes a configuration having an exterior wire frame <NUM> that can be disposed about the exterior of a filter media. The exterior wire frame <NUM> can include one or more axial frames <NUM> configured to be shaped complementary to a filter media to be disposed within the center of the scaffold pleat guide <NUM>. The exterior wire frame <NUM> can include a plurality of longitudinal rods <NUM> extending between valleys <NUM> on each of the axial frames <NUM>. The longitudinal rods <NUM> maintain axial spacing between two axial frames. In some embodiments, the number of axial frames <NUM> used in the scaffold pleat guide <NUM> can be greater than or equal to two, three, four, five, six, or seven axial frames <NUM>.

The axial frame <NUM> can include a plurality of guide peaks <NUM> and guide valleys <NUM> as described elsewhere herein, where that there can be one guide peak <NUM> per pleat in the filter medium it is configured to support. It will be appreciated that in some embodiments, the axial frame <NUM> can include a plurality of guide peaks <NUM> such that it can be configured to support or skip every nth pleat of a pleated filter media, where n can be <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or more. The scaffold pleat guide <NUM> shown in <FIG> includes a configuration having an interior wire frame <NUM> that can be disposed within the interior of a filter media having a corresponding shape. The interior wire frame <NUM> includes a plurality of longitudinal rods <NUM> that are configured to be disposed within the pleat peaks of a filter media. The interior wire frame <NUM> can further include a first axial frame <NUM> including one or more axial struts <NUM>, and a second axial frame <NUM> including one or more axial struts <NUM>. Each axial frame <NUM>, <NUM> can include a plurality of guide peaks <NUM> and guide valleys <NUM> as described elsewhere herein, so that there can be one guide peak <NUM> per pleat in the filter medium it is configured to support. It will be appreciated that in some embodiments, each axial frame can include a plurality of guide peaks <NUM> such that it can be configured to support or skip every nth pleat of a pleated filter media, where n can be <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or more.

The end caps and pleat guide structures described herein can be formed using the process of additive manufacturing, referred to herein as <NUM>-dimensional (3D) printing. The end caps and pleat guide structures generated using 3D printing can include unique and fine structural detail, including those having a high aspect ratio. The fine features incorporated into the end caps and pleat guides can include, but is not to be limited to, a honeycomb pore structure having a varying distribution of varying pore sizes, a honeycomb pore structure having a uniform distribution of uniform pores sizes, fine struts, fine mesh structures, a gradient pore structures throughout the material, threads, ridges, micro-surfaced to confer roughness and additional surface area, open cavities, central apertures, and the like. In various embodiments, the pleat guides can be 3D printed to include guide peaks and valleys that are highly porous to allow for the transfer of a fluid at the pleat guide/pleated filter media interface. In other embodiments, the 3D printing process can mix various materials to generate the end caps and pleat guides.

Various materials are suitable for creating the end caps and pleat guides described herein. The materials include, but are not to be limited to, thermoplastic polymers including, but not to be limited to polyamides, polypropylene, polyurethane, polyethylene, polylactic acid, acrylonitrile butadiene styrene, styrene, and copolymers, mixtures, or derivatives thereof.

It will be appreciated that the pleat guides herein can be constructed of a variety of materials that can withstand a range of pressures, temperatures, and chemical conditions in the environments in which they are used in operation. The pleat guides should further be constructed of materials that are at least as strong as the filter media that they are designed to support.

Many of the end caps and pleat guides described herein can be made by injection molding manufacturing methods. Examples of procedures for forming end caps and pleat guides by injection molding manufacturing methods are known in the art.

The material of an end cap or pleat guide structure described herein can be porous, such as to allow fluid to flow through the structure. This porosity can be accomplished during a printing process by defining many and frequent open spaces interspersed with solid material portions. An example of a pleat guide structure defining four open areas is shown in <FIG>. These open areas allow for fluid to flow through the structure.

In some embodiments, the open area of an end cap or pleat guide structure can be greater than or equal to <NUM> %, <NUM> %, <NUM> %, <NUM> %, <NUM> %, <NUM> %, <NUM> %, <NUM> %, or <NUM> %. In some embodiments, the open area can be less than or equal to <NUM> %, <NUM> %, <NUM> %, <NUM> %, <NUM> %, <NUM> %, <NUM> %, <NUM> %, or <NUM> %. In some embodiments, the open area can fall within a range of <NUM> % to <NUM> %, or <NUM> % to <NUM> %, or <NUM> % to <NUM> %, or <NUM> % to <NUM> %, or <NUM> % to <NUM> %, or <NUM> % to <NUM> %, or <NUM> % to <NUM> %, or <NUM> % to <NUM> %, or can be about <NUM> %.

The analysis of percent open area can be performed by taking a photograph of the end cap or pleat guide and counting up open pixels vs. total pixels. The analysis can be performed an outer perimeter of an end cap or pleat guide. Alternatively, if the end cap or pleat guide or defines a center aperture, the analysis of percent open area can analyzed based on the area between the center aperture <NUM> or <NUM> and an outer perimeter of the end cap or pleat guide.

Another way that porosity can also be accomplished is by choosing material for the structure that is itself porous or can be modified after printing to be porous. Some 3D printing materials incorporate particles, such as spheres, of thermoplastic material of a different type than the remainder of the material. These particles can be partially cured and dissolved out of the structure after printing. Another option is to selectively bake or etch away particles that are included in the materials of the structure. These processes result in void spaces within the printed materials, increasing the porosity of the material.

For the purpose of this disclosure, the term "pore size" refers to spaces formed by materials within a printed structure. The pore size of the media can be and estimated by reviewing electron photographs of the media. The average pore size of a media can also be calculated using a Capillary Flow Porometer having model no. APP <NUM> AEXSC available from Porous Materials Inc. of Ithaca, NY.

In the context of filtration assemblies used for gas separation, in some embodiments, the average pore size for the printed material can be greater than or equal to <NUM> nanometers, <NUM> nanometers, <NUM> nanometers, <NUM> nanometers, or <NUM> nanometers. In some embodiments, the average pore size can be less than or equal to <NUM> nanometers, <NUM> nanometers, <NUM> nanometers, <NUM> nanometers, or <NUM> nanometers. In some embodiments, the average pore size can fall within a range of <NUM> nanometers to <NUM> nanometers, or <NUM> nanometers to <NUM> nanometers, or <NUM> nanometers to <NUM> nanometers, or <NUM> nanometers to <NUM> nanometers, or can be about <NUM> nanometers.

In other filtration contexts where preservation of the permeability of an existing media is a priority, such as ePTFE, in some embodiments, the average pore size can be greater than or equal to <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, or <NUM> microns. In some embodiments, the average pore size can be less than or equal to <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, or <NUM> microns. In some embodiments, the average pore size can fall within a range of <NUM> microns to <NUM> microns, or <NUM> microns to <NUM> microns, or <NUM> microns to <NUM> microns, or <NUM> microns to <NUM> microns, or <NUM> microns to <NUM> microns, or <NUM> microns to <NUM> microns, or <NUM> microns to <NUM> microns, or <NUM> microns to <NUM> microns, or <NUM> microns to <NUM> microns, or <NUM> microns to <NUM> microns, or can be about <NUM> microns.

In other filtration contexts such as the semiconductor fields, where preservation of the permeability of an existing media is a priority, in some embodiments, the average pore size can be greater than or equal to <NUM> micrometers, <NUM> micrometers, <NUM> micrometers, <NUM> micrometers, or <NUM> micrometers, or can be an amount falling within a range between any of the foregoing.

In the context of filtration assemblies that use nonwoven composite materials, in some embodiments, the average pore size of the printed material can be greater than or equal to <NUM> microns, <NUM> microns, <NUM> microns, or <NUM> microns. In some embodiments, the average pore size can be less than or equal to <NUM> microns, <NUM> microns, <NUM> microns, or <NUM> microns. In some embodiments, the average pore size can fall within a range of <NUM> microns to <NUM> microns, or <NUM> microns to <NUM> microns, or <NUM> microns to <NUM> microns, or can be about <NUM> microns.

In the context of filtration media where it is important to minimize pressure drop, the average pore size of the printed material, in some embodiments, the average pore size can be greater than or equal to <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. In some embodiments, the average pore size can be less than or equal to <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. In some embodiments, the average pore size can fall within a range of <NUM> to <NUM>, or <NUM> to <NUM>, or <NUM> to <NUM>, or <NUM> to <NUM>, or <NUM> to <NUM>, or can be about <NUM>.

It should be noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the content clearly dictates otherwise. It should also be noted that the term "or" is generally employed in its sense including "and/or" unless the content clearly dictates otherwise.

As used herein, the recitation of numerical ranges by endpoints shall include all numbers subsumed within that range (e.g., <NUM> to <NUM> includes <NUM>, <NUM>, <NUM>, <NUM>, etc.).

The headings used herein are provided for consistency with suggestions under <NUM> CFR <NUM> or otherwise to provide organizational cues. These headings shall not be viewed to limit or characterize the invention(s) set out in any claims that may issue from this disclosure. As an example, although the headings refer to a "Field," such claims should not be limited by the language chosen under this heading to describe the so-called technical field. Further, a description of a technology in the "Background" is not an admission that technology is prior art to any invention(s) in this disclosure. Neither is the "Summary" to be considered as a characterization of the invention(s) set forth in issued claims.

Claim 1:
A filter assembly component comprising:
a pleat guide (<NUM>) comprising a repeating pattern comprising a plurality of peaks (<NUM>) and a plurality of valleys (<NUM>) distributed about a circumference of the pleat guide (<NUM>);
wherein the plurality of peaks (<NUM>) and the plurality of valleys (<NUM>) are configured to interface with a pleated filter media (<NUM>) to maintain pleat spacing between corresponding pleats of the pleated filter media (<NUM>);
characterized in that the pleat guide (<NUM>) defines a plurality of hollow passages (<NUM>) extending from a central portion of the pleat guide (<NUM>) to a circumferential surface of the pleat guide, each hollow passage (<NUM>) connecting to a central aperture (<NUM>) at the central portion and connecting to an outer circumferential aperture (<NUM>) at the circumferential surface of the pleat guide, wherein the plurality of central apertures (<NUM>) are connected to a hollow central coupling ring (<NUM>) disposed at the center of each of the interior pleat guides (<NUM>),
wherein the pleat guide (<NUM>) further defines a fluid inlet port (<NUM>) in fluid communication with the plurality of hollow passages (<NUM>),
and wherein each central coupling ring (<NUM>) is connected by a longitudinal hollow tube (<NUM>), which is further coupled to the fluid inlet port (<NUM>).