Patent Application
20210178309
The present application relates to filter media.
Internal combustion engines generally combust a mixture of fuel (e.g., gasoline, diesel, natural gas, etc.) and air. Lubrication oil is also supplied to the engine to lubricate the various moving components of the engine. Either prior to entering the engine or during engine operation, the intake air, fuel, lubrication oil, and other fluids are typically passed through filtration systems to remove contaminants (e.g., dust, water, oil, etc.) from the fluids. The filtration systems include filter elements having filter media. As the fluid passes through the filter media, the filter media removes at least a portion of the contaminants in the fluid. Each filter element has an associated filtration efficiency. The filtration efficiency is a numerical representation of the filter element's effectiveness in removing contaminants from the fluid. The filtration efficiency of a filter element can vary over time. The efficiency of the filter element can be impacted by the design of the filter element (e.g., panel, pleated, non-pleated, cylindrical, membrane, etc.), the design of the filtration system, the operating conditions of the filtration system, and the utilized filter media (e.g., paper, fiberglass, polyester, foam, nanofiber, etc.).
Certain filtration systems incorporate multiple filter elements having different types of filter media to balance filtration efficiency, filter cartridge longevity, and cost. Such filters are also typically a combination of different filter elements having different filtering characteristics or add an additional higher efficiency filter cartridge to an existing standard efficiency filter cartridge. For example, as shown in
Flow through the above described parallel flow dual element filter is split between the two filter cartridges 102 and 104 based on a number of factors. For example, the amount of fluid flowing through the first filter cartridge 102 versus the amount of fluid flowing through the second filter cartridge 104 may be affected by the openings between endplates, the flow orifice between the two filter cartridges 102 and 104, the media permeability (i.e., the media's resistance to flow), and the like. Accordingly, managing and maintaining the flow split between the two filter cartridges 102 and 104 is difficult and requires manipulation of various parameters of the filtration system 100.
An example embodiment relates to a filter cartridge. The filter cartridge includes a first endplate, a second endplate, and a filter media positioned between the first endplate and the second endplate and spanning an axial length between the first endplate and the second endplate. The filter media has a variable filtering efficiency that varies across the axial length. The filter media includes a first filter media portion having a first filtering efficiency and a first filter media axial length spanning the axial length. The filter media also includes a second filter media portion having a second filtering efficiency. The second filter media portion is coupled to the first filter media portion and spans a second filter media axial length. The second filter media axial length is less than the first filter media axial length of the filter media, thereby creating a first zone of the filter media and a second zone of the filter media. The first zone includes only the first filter media portion, and the second zone including both the first filter media portion and the second filter media portion.
Another example embodiment relates to filter media. The filter media includes a first filter media portion having a first filtering efficiency. The first filter media portion spans a first filter media width (also referred to as a slit width in some specific implementations). The filter media further includes a second filter media portion having a second filtering efficiency. The second filter media portion is coupled to the first filter media portion and spans a second filter media width. The second filter media width extends in the same direction as the first filter media width. The second filter media width is less than the first filter media width, thereby creating a first zone of the filter media and a second zone of the filter media. The first zone including only the first filter media portion, and the second zone including both the first filter media portion and the second filter media portion.
A further example embodiment relates to filter media. The filter media includes a first filter media portion having a first filtering efficiency and a first filter media width. The filter media includes a second filter media portion having a second filtering efficiency and a second filter media width. The second filter media portion is coupled to the first filter media portion, thereby forming an overlap zone having both the first filter media and the second filter media. The first filter media and the second filter media combining to have a combined width that is smaller than a sum of the first filter media width and the second filter media width.
These and other features, together with the organization and manner of operation thereof, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like elements have like numerals throughout the several drawings described below.
Referring to the figures generally, a variable efficiency filter media is described. The variable efficiency filter media is a composite media foamed of at least two different types of filter media, such as a standard efficiency media and a high efficiency media. In some arrangements, the standard efficiency media forms a structural backbone for holding the other, higher efficiency media. Accordingly, the variable efficiency filter media has at least two different efficiency levels. The different efficiency levels can be spread across different zones. The variable efficiency filter media permits the efficiency ratio of each zone to be adjusted within a single filter element thereby allowing the filter element to meet various filter performance requirements. The filter media types for both the standard media and the high efficiency media can be made from spun media, melt blown media, nanofiber media, micro-glass media, cellulose media, carded staple fiber media, and the like. The variable efficiency filter media may be produced by any of an air laid process, a wet laid process, a lamination process, a pleating process, an ultrasonic bonding process, or the like.
Referring to
The variable efficiency filter media 200 includes a second filter media portion 204. The second filter media portion 204 may be spun media, melt blown media, nanofiber media, micro-glass media, cellulose media, carded staple fiber media, or the like. The second filter media portion 204 has a different filtering efficiency than the first filter media portion 202. In some arrangements, the second filter media portion 204 has a higher filtering efficiency than the first filter media portion 202 (e.g., by compressing/calendaring the second filter media portion 204 to zones within the first filter media portion 202 to increase the efficiency of the first media 202 during production). The second filter media portion 204 is connected to and coupled to the first filter media portion 202 via an air laid process, a wet laid process, a lamination process, a pleating process, an ultrasonic bonding process, or the like. As used herein, when two filter media portions or layers are coupled to each other, the second filter media layer, for example, may be combined with, integrated with, overlaid onto, sprayed over, formed onto, underlain onto, or otherwise connected to the first filter media. In addition or alternatively, when two filter media portions or layers are coupled to each other, the first filter media type may be manufactured in a first orientation (e.g., having fibers or pleats in a first direction, such as horizontal with respect to gravity) and positioned in a second orientation with respect to the second filter media (e.g., having fibers or pleats in a second direction, such as vertical with respect to gravity). The second filter media portion 204 may be sealed to the first filter media portion 202 at an edge of the second filter media portion 204. The use of an ultrasonic bonding process additionally provides for a differential pressure across a gradient of the variable efficiency filter media. Additionally, to assist with manufacturing via the ultrasonic bonding, indicators can be incorporated onto the ultrasonic bonding anvil drum to give visual assistance for subsequent manufacturing process (e.g., making it easier for the manufacturing line technician to visually see top and bottom portions of the media roll or pleated media packs).
The second filter media portion 204 spans across a distance less than the filter media width (i.e., the axial length of the variable efficiency filter media 200) of the variable efficiency filter media 200. Accordingly, the variable efficiency filter media 200 has two separate zones of filtering efficiency: a first zone having only the first filter media portion 202 and a second zone having both the first filter media portion 202 and the second filter media portion 204. Each of the two zones has a different filtering efficiency. The overall efficiency of the variable efficiency filter media 200 can be tuned by adjusting the widths of each strip of filter media and by selecting appropriate filter media for each of the strips. However, as described in more detail with respect to
Referring to
In an alternative arrangement, the third filter media portion 206 is coupled to and directly connected to the first filter media portion 202 via an air laid process, a wet laid process (e.g., by compressing/calendaring the third filter media portion 206 to zones within the first filter media portion 202 to increase the efficiency of the first media 202 during production), a lamination process, a pleating process, an ultrasonic bonding process, or the like. The third filter media portion 206 spans across a distance less than the filter media width across the width of the variable efficiency filter media 210. In this arrangement, the third filter media portion 206 may be sealed to the first filter media portion 202 at an edge of the third filter media portion 206. The widths of the strips of the first, second, and third filter media portions 202, 204, and 206 can be the same or different. In this embodiment, the variable efficiency filter media 210 has three separate zones of filtering efficiency: a first zone having only the first filter media portion 202, a second zone having both the first filter media portion 202 and the second filter media portion 204, and a third zone having both the first filter media portion 202 and the third filter media portion 206. Each of the three zones has a different filtering efficiency. The overall efficiency of the variable efficiency filter media 210 can be tuned by adjusting the widths of each strip of filter media and by selecting appropriate filter media for each of the strips.
Referring to
In an alternative arrangement, the fourth filter media portion 208 is coupled to the first filter media portion 202 via an air laid process, a wet laid process (e.g., by compressing/calendaring the fourth filter media portion 208 to zones within the first filter media portion 202 to increase the efficiency of the first media 202 during production), a lamination process, a pleating process, an ultrasonic bonding process, or the like. In such an arrangement, the fourth filter media portion 208 may be sealed to the first filter media 202 at an edge of the fourth filter media portion 208. The fourth filter media portion 208 spans across a distance less than the filter media width across the width of the variable efficiency filter media 220. The widths of the strips of the first, second, third, and fourth filter media portions 202, 204, 206, and 208 can be the same or different. The variable efficiency filter media 220 of this embodiment has four separate zones of filtering efficiency: a first zone having only the first filter media portion 202, a second zone having both the first filter media portion 202 and the second filter media portion 204, a third zone having both the first filter media portion 202 and the third filter media portion 206, and a fourth zone having both the first filter media portion 202 and the fourth filter media portion 208. Each of the three zones has a different filtering efficiency. The overall efficiency of the variable efficiency filter media 220 can be tuned by adjusting the widths of each strip of filter media and by selecting appropriate filter media for each of the strips.
Any number of different filtering efficiency zones can be created over a base layer of the first filter media portion 202. In some arrangements, a gradient of different filtering efficiency zones can be created over the base layer of the first filter media portion 202 by layering a high number of alternative filter media types onto the first filter media portion 202 to increase the filtering efficiency across the first filter media portion 202.
The above described variable efficiency filter media 200, 210, and 220 can be utilized in filter cartridges. For example, the variable efficiency filter media 200, 210, and 220 can be pleated into a standard pleat pack that is used to produce a filter cartridge that does not require a parallel flow filter design to achieve the variable filtering efficiencies. Thus, the variable efficiency filter media 200, 210, and 220 reduce filter cartridge design complexity and costs by eliminating the need for two cartridges of different filtering efficiencies and reducing the potential for fluid bypass and leaks. The filter cartridges can be of any shape, such as a cylindrical filter cartridge, a panel filter cartridge, or the like. Referring to
Similar filter cartridges can be constructed with variable efficiency filter media 210 and 220. For example,
Referring to
The above-described filter cartridges utilizing the variable efficiency filter medias provide for a cost-effective filter cartridge by eliminating the need for two cartridges in a parallel flow or shunt filter design (e.g., as described above with respect to
Referring to
Continuing on to
In the above-described methods of producing the variable efficiency filter media, certain production parameters can be adjusted to affect the filtering efficiency of the variable efficiency filter media. For example, during a polymeric air laid process of making a particular filter media, differing material viscosities can be used to obtain differing fiber diameters across the web of a dual supply of polymer. Additionally, different die geometry can be used with an air laid process (e.g., alternative hole diameters across the die and the web). Further, the die geometry can be altered to provide an air gap alteration of 1.6 mm→1.0 mm (e.g., in wave form or as a right angle/squared off manner. The die geometry can be further altered to add laval nozzles in areas across the air lips of the air laid process. Further, air flow can be increased or decreased (e.g., increasing or decreasing the air flow volume, accelerating or decelerating the air flow, etc.) during the air laid process. Still further, high compression and/or calendaring of areas or zones of the filter media in the cross direction can be done to alter the filtering efficiency of the variable efficiency filter media.
Referring to
Variable efficiency filter media can also be produced from a single type of filter media (e.g., standard filter media) by folding the filter media over itself or by overlapping multiple layers of the filter media. For example, as shown in
The above-described variable efficiency media provides an axial variation of filtering efficiency across the filter media width in a single media. The single media may incorporate multiple types of media into the single media to provide zones or areas of an increased overall efficiency performance. The increased efficiency depends on the effective area ratios of the filter media (e.g., the ratio of standard filter media to high efficiency filter media), the efficiency of the standard filter media, and the efficiencies of any added filter material. For example, Table 1 shows different efficiency ratios and demonstrates improvements in small particulate removal as the area of the higher efficiency media is increased.
The improved efficiency is also shown in graph 1100 of
Referring to
As described above, the variable efficiency media may be formed by ultrasonically bonding different layers of filter media to each other. In certain arrangements where a layer of media does not extend the full length of a filter cartridge (i.e., does not span the entire distance between two endcaps), the ultrasonic bonding of the adjacent layers of filter media can provide additional structural support to the filter cartridge. In some arrangements, the ultrasonic bonding may occur at an edge of the second filter media through a continuous weld. In such arrangements, the continuous weld may form a seal between the first filter media and the second filter media. One such arrangement is described below with respect to
As shown in
The above-described variable efficiency media combines multiple media performances, high and standard efficiency, into a single, variable efficiency filter media. The variable efficiency media may include multiple variations (e.g., arrangements of standard efficiency filter media and the high efficiency filter media) or gradient structure of increasingly higher efficiency media into one composite media. The variable efficiency filter media can be formed by methods of intentional altering media formulation or formation to alter media physical characteristics (e.g., pore size, fiber diameter, etc.) or by simple insertion of higher efficiency layers into the standard efficiency filter media, which alters the overall media performance in the cross direction and/or in the linear direction of the media web. This alternation achieves a targeted overall efficiency performance when the media is pleated into a filtration element. Benefits of the variable efficiency media over standard efficiency media may include improved filter life, lower overall filter restriction, and increased capacity for contaminant while maintaining efficiency. Further, the described variable efficiency media provide an improved way to manage the flow balance over existing parallel flow elements. The variable efficiency media further allows for simplified filter cartridge design where the ratio of high and standard efficiency media width can be easily changed. The easily changeable ratio allows for easy determination and predictability of the flow balance through each media in the variable efficiency media. This design flexibility allows for filter performance changes without altering or changing hardware.
The above-described variable efficiency media may be used in a variety of different types of filtration systems, such as fuel filtration systems, lubricant filtration systems, hydraulic fluid filtration systems, water filtration systems, and the like. For example, the lubrication filtration systems typically have to filter viscous liquids, which can present filtration issues. At low temperature, lube oil viscosity is high and the oil needs to have large pore sizes in the filter media to flow through. However, the large pore size of the media required will have low particle removal efficiency, which can result in excess engine component wear. Use of the above-described variable efficiency media permits viscous lubricant flow through the lubricant system. Additionally, as the lube heats up and becomes less viscous, the lube passes through the higher efficiency portions of the variable efficiency filter media, which improves the total system filtration efficiency.
In addition to the above described variable efficiency media that layers various efficiency media on top of one another, a similar effect may be achieved by intentionally altering a media formulation or formation to alter media physical characteristics (e.g., pore size, fiber diameter, etc.) across a length of the media.
It should be noted that any use of the term “exemplary” herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).
The terms “coupled,” “connected,” “overlaid,” “underlaid,” “interlaid,” and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.
References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below,” etc.) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure. Specifically, media described as overlaid can be underlain, for example. Alternatively, the orientation of media layers in manufacturing the composite can be reversed in order from the final element orientation. A combination of overlaid and underlain media—with three or more media—may also be implemented.
It is important to note that the construction and arrangement of the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Additionally, features from particular embodiments may be combined with features from other embodiments as would be understood by one of ordinary skill in the art. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.
This application claims priority to U.S. Provisional Patent Application No. 62/208,412, entitled “VARIABLE EFFICIENCY FILTRATION MEDIA,” filed on Aug. 21, 2015 and the contents of which herein incorporated by reference in the entirety and for all purposes.
| Number | Date | Country | |
|---|---|---|---|
| 62208412 | Aug 2015 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15750744 | Feb 2018 | US |
| Child | 17180149 | US |
