阅读说明：本技术 过滤介质、过滤介质包以及过滤元件 (Filter medium, filter medium pack and filter element ) 是由 D·E·阿达梅克 S·M·布朗 M·A·萨拉 于 2019-06-11 设计创作，主要内容包括：实施例包括一种空气过滤介质元件(10),所述空气过滤介质元件包括多层带槽介质,每层包括饰面片材和带槽片材,所述带槽片材包括第一多个槽和第二多个槽,所述第一多个槽和所述第二多个槽以平行流构型安排；其中,所述第一多个槽和所述第二多个槽在槽形状、槽尺寸、槽高度、槽宽度、槽截面积或过滤介质方面呈现出规则重复的差异。(Embodiments include an air filtration media element (10) comprising a plurality of layers of fluted media, each layer comprising a facing sheet and a fluted sheet, the fluted sheet comprising a first plurality of flutes and a second plurality of flutes arranged in a parallel flow configuration; wherein the first and second plurality of flutes exhibit a regularly repeating difference in flute shape, flute size, flute height, flute width, flute cross-sectional area, or filter media.)

1. An air filter element for removing particulates from an air stream, the air filter element comprising:

a) a first plurality of slots; and

b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of flutes exhibiting a difference in flute shape, flute size, flute height, flute width, flute length, flute cross-sectional area, or filter media relative to the first plurality of flutes;

wherein the first and second pluralities of flutes have a common upstream face and a common downstream face; and is

Wherein, when loading the filter element with dust at a substantially constant speed, the first and second plurality of flutes perform the following:

a) the first and second pluralities of slots have substantially equal initial pressure drops from the upstream face to the downstream face;

b) the initial velocity of the first plurality of slots is greater than the initial velocity of the second plurality of slots;

c) during the dust load:

i) the pressure drops across the first and second pluralities of slots remain substantially equal relative to each other as the velocities of the first and second pluralities of slots vary relative to each other; and

ii) the velocity across the first plurality of troughs decreases and the velocity across the second plurality of troughs increases at least until the velocity across the second plurality of troughs is greater than the velocity across the first plurality of troughs.

2. An air filtration media element for removing particulates from an air stream as claimed in any of claims 1 and 3 to 18 wherein the transition from the velocity of the first plurality of flutes being greater than the velocity of the second plurality of flutes to the velocity of the second plurality of flutes being greater than the velocity of the first plurality of flutes occurs before the media element is loaded to 10% of dust loading capacity.

3. An air filtration media element for removing particulates from an air stream as claimed in any of claims 1 to 2 and 4 to 18 wherein the transition from the velocity of the first plurality of flutes being greater than the velocity of the second plurality of flutes to the velocity of the second plurality of flutes being greater than the velocity of the first plurality of flutes occurs before the media element is loaded to 15% of dust loading capacity.

4. An air filtration media element for removing particulates from an air stream as claimed in any of claims 1 to 3 and 5 to 18 wherein the transition from the velocity of the first plurality of flutes being greater than the velocity of the second plurality of flutes to the velocity of the second plurality of flutes being greater than the velocity of the first plurality of flutes occurs before the media element is loaded to 20% of dust loading capacity.

5. The air filter media element of any of claims 1-4 and 6-18, wherein the first plurality of flutes are arranged in a first plurality of layers of the fluted media and the second plurality of flutes are arranged in a second plurality of layers of the fluted media.

6. The air filtration media element of any of claims 1-5 and 7-18, wherein the first plurality of flutes constitute 10% to 90% of the volume of the media element and the second plurality of flutes constitute 90% to 10% of the volume of the media element.

7. The air filtration media element of any of claims 1-6 and 8-18, wherein the first plurality of flutes constitute 20-40% and the second plurality of flutes constitute 60-80% of the volume of the media element.

8. The air filtration media element of any of claims 1-7 and 9-18, wherein the first plurality of flutes constitute 40-60% and the second plurality of flutes constitute 60-40% of the volume of the media element.

9. The air filtration media element of any of claims 1-8 and 10-18, wherein the first plurality of flutes constitute 10% to 90% of the media surface area of the media element and the second plurality of flutes constitute 90% to 10% of the media surface area of the media element.

10. The air filtration media element of any of claims 1-9 and 11-18, wherein the first plurality of flutes constitute 20% to 40% and the second plurality of flutes constitute 60% to 80% of the media surface area of the media element.

11. The air filtration media element of any of claims 1-10 and 12-18, wherein the first plurality of flutes constitute 40% to 60% and the second plurality of flutes constitute 60% to 40% of the media surface area of the media element.

12. The air filter media element of any of claims 1-11 and 13-18, wherein the first plurality of flutes constitute 10% to 90% of the inlet face of the media element and the second plurality of flutes constitute 90% to 10% of the inlet face of the media element.

13. The air filter media element of any of claims 1-12 and 14-18, wherein the first plurality of flutes constitute 20% to 40% and the second plurality of flutes constitute 60% to 80% of the inlet face of the media element.

14. The air filter media element of any of claims 1-13 and 15-18, wherein the first plurality of flutes constitute 40% to 60% and the second plurality of flutes constitute 60% to 40% of the inlet face of the media element.

15. The air filter media element of any of claims 1-14 and 16-18, further comprising a third plurality of flutes arranged in parallel flow with the first and second plurality of flutes;

wherein the first, second, and third pluralities of flutes exhibit differences in flute shape, flute size, flute height, flute width, flute length, flute cross-sectional area, or filter media.

16. The air filter media element of any of claims 1-15 and 17-18, wherein each of the first, second, and third pluralities of flutes are arranged in separate layers.

17. The air filter media element of any of claims 1-16 and 18, wherein the multilayer media is arranged in a rolled configuration or a stacked configuration.

18. The air filter media element of any of claims 1-17, wherein the differences in flute shape, flute size, flute height, flute width, flute length, flute cross-sectional area, or filter media are regular and repeating.

19. An air filter media element for removing particulates from an air stream, the air filter media element comprising:

a) a first plurality of slots; and

b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of flutes exhibiting a difference in flute shape, flute size, flute height, flute width, flute cross-sectional area, flute length, or filter media relative to the first plurality of flutes;

wherein the first and second pluralities of flutes have a common upstream face and a common downstream face;

wherein, when dust is loaded in the filter element, the first and second plurality of flutes perform as follows:

a) the first plurality of slots have an initial pressure drop Δ P over the second plurality of slots when the first and second plurality of slots are independently tested at the same media element velocity_2,iLow initial pressure drop Δ P_1,i(ii) a And an initial slope Δ (Δ P) of a pressure drop/load curve of the first plurality of slots at time a_1,i/L_1,i)_aA pressure drop/load curve greater than the second plurality of slotsInitial slope Δ (Δ P)_2,i/L_2,i)_a：

Δ(ΔP_1,i/L_1,i)_a>Δ(ΔP_2,i/L_2,i)_a

b) Initial velocity V of the first plurality of slots at time a if the first and second plurality of slots are combined and tested simultaneously in parallel flow_1,aGreater than the initial velocity V of the second plurality of slots at time a_2,a：

V_1,a>V_2,a

c) An intermediate second velocity V of the first plurality of slots at a subsequent time b if the first and second plurality of slots are combined and tested simultaneously in parallel flow_1,bEqual to the intermediate speed V of said second plurality of grooves_2,b：

V_1,b＝V_2,b

d) Third speed V of the first plurality of slots at a subsequent time c if the first and second plurality of slots are combined and tested simultaneously in parallel flow_1,cA third velocity V less than the second plurality of grooves_2,c：

V_1,c<V_2,c

20. The air filter media element of any of claims 19 and 21-33, wherein the first plurality of flutes are arranged in a first plurality of layers of the fluted media and the second plurality of flutes are arranged in a second plurality of layers of the fluted media.

21. The air filtration media element of any of claims 19-20 and 22-33, wherein the first plurality of flutes constitute 10% to 90% of the volume of the media element and the second plurality of flutes constitute 90% to 10% of the volume of the media element.

22. The air filtration media element of any of claims 19-21 and 23-33, wherein the first plurality of flutes constitute 20-40% and the second plurality of flutes constitute 60-80% of the volume of the media element.

23. The air filtration media element of any of claims 19-22 and 24-33, wherein the first plurality of flutes constitute 40-60% and the second plurality of flutes constitute 60-40% of the volume of the media element.

24. The air filtration media element of any of claims 19-23 and 25-33, wherein the first plurality of flutes constitute 10% to 90% of the media surface area of the media element and the second plurality of flutes constitute 90% to 10% of the media surface area of the media element.

25. The air filtration media element of any of claims 19-24 and 26-33, wherein the first plurality of flutes constitute 20% to 40% and the second plurality of flutes constitute 60% to 80% of the media surface area of the media element.

26. The air filtration media element of any of claims 19-25 and 27-33, wherein the first plurality of flutes constitute 40-60% and the second plurality of flutes constitute 60-40% of the media surface area of the media element.

27. The air filter media element of any of claims 19-26 and 28-33, wherein the first plurality of flutes constitute 10% to 90% of the inlet face of the media element and the second plurality of flutes constitute 90% to 10% of the inlet face of the media element.

28. The air filter media element of any of claims 19-27 and 29-33, wherein the first plurality of flutes constitute 20% to 40% and the second plurality of flutes constitute 60% to 80% of the inlet face of the media element.

29. The air filter media element of any of claims 19-28 and 30-33, wherein the first plurality of flutes constitute 40-60% and the second plurality of flutes constitute 60-40% of the inlet face of the media element.

30. The air filter media element of any of claims 19-29 and 31-33, further comprising a third plurality of flutes arranged in parallel flow with the first and second plurality of flutes;

wherein the first, second, and third pluralities of flutes exhibit differences in flute shape, flute size, flute height, flute width, flute length, flute cross-sectional area, or filter media.

31. The air filter media element of any of claims 19-30 and 32-33, wherein each of the first, second, and third pluralities of flutes are arranged in separate layers.

32. The air filter media element of any of claims 19-31 and 33, wherein the multilayer media is arranged in a rolled configuration or a stacked configuration.

33. The air filter media element of any of claims 19-32, wherein the differences in flute shape, flute size, flute height, flute width, flute cross-sectional area, or filter media are regular and repeating.

34. An air filter element for removing particulates from an air stream, the air filter element comprising:

a) a first plurality of slots; and

b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of flutes exhibiting a difference in flute shape, flute size, flute height, flute width, flute cross-sectional area, flute length, or filter media relative to the first plurality of flutes;

wherein the first and second pluralities of flutes have a common upstream face and a common downstream face;

wherein when simultaneously loading dust under parallel flow conditions, and when loading a point of water having a pressure drop of at least 10 inches to the media element, the first and second plurality of slots perform the following:

a) time-averaged velocity of the first plurality of slotsLess than the time-average velocity of the entire filter elementAnd the time-average velocity of the second plurality of slotsGreater than the time-average speed of the filter element

b) A change in load Δ L of the first plurality of grooves₁Equal to the time-averaged velocity L in the first plurality of slots_{1,(V1 avg)}Load of the first plurality of slots tested down minus time-averaged speed L of the component_{1, (V element avg)}The following tested loads of the first plurality of slots:

ΔL₁＝L_{1,(V1 avg)}-L_{1, (V element avg)}

ΔL₁>0

c) A change in load Δ L of the second plurality of slots₂Equal to the time-averaged velocity L at the second plurality of slots_{2,(V2 avg)}Load of the second plurality of slots tested down minus time-averaged speed L of the component_{2, (V element avg)}(ii) the load of the second plurality of slots tested as follows:

ΔL₂＝L_{2,(V2 avg)}-L_{2, (V element avg)}

ΔL₂<0

d)ΔL₁And Δ L₂The sum is more than 0:

ΔL₁+ΔL₂>0

35. the air filter media element of any of claims 34 and 36-48, wherein the first plurality of flutes are arranged in a first plurality of layers of the fluted media and the second plurality of flutes are arranged in a second plurality of layers of the fluted media.

36. The air filtration media element of any of claims 34-35 and 37-48, wherein the first plurality of flutes constitute 10% to 90% of the volume of the media element and the second plurality of flutes constitute 90% to 10% of the volume of the media element.

37. The air filtration media element of any of claims 34-36 and 38-48, wherein the first plurality of flutes constitute 20-40% and the second plurality of flutes constitute 60-80% of the volume of the media element.

38. The air filtration media element of any of claims 34-37 and 39-48, wherein the first plurality of flutes constitute 40-60% and the second plurality of flutes constitute 60-40% of the volume of the media element.

39. The air filtration media element of any of claims 34-38 and 40-48, wherein the first plurality of flutes constitute between 10% and 90% of the media surface area of the media element and the second plurality of flutes constitute between 90% and 10% of the media surface area of the media element.

40. The air filtration media element of any of claims 34-39 and 41-48, wherein the first plurality of flutes constitute 20% to 40% and the second plurality of flutes constitute 60% to 80% of the media surface area of the media element.

41. The air filtration media element of any of claims 34-40 and 42-48, wherein the first plurality of flutes constitute 40-60% and the second plurality of flutes constitute 60-40% of the media surface area of the media element.

42. The air filter media element of any of claims 34-41 and 43-48, wherein the first plurality of flutes constitute 10% to 90% and the second plurality of flutes constitute 90% to 10% of the inlet face of the media element.

43. The air filter media element of any of claims 34-42 and 44-48, wherein the first plurality of flutes constitute 20% to 40% and the second plurality of flutes constitute 60% to 80% of the inlet face of the media element.

44. The air filter media element of any of claims 34-43 and 45-48, wherein the first plurality of flutes constitute 40-60% and the second plurality of flutes constitute 60-40% of the inlet face of the media element.

45. The air filter media element of any of claims 34-44 and 46-48, further comprising a third plurality of flutes arranged in parallel flow with the first and second plurality of flutes;

wherein the first, second, and third pluralities of flutes exhibit differences in flute shape, flute size, flute height, flute width, flute length, flute cross-sectional area, or filter media.

46. The air filter media element of any of claims 34-45 and 47-48, wherein each of the first, second, and third pluralities of flutes are arranged in separate layers.

47. The air filter media element of any of claims 34-46 and 48, wherein the multi-layer media is arranged in a rolled configuration or a stacked configuration.

48. The air filter media element of any of claims 34-47, wherein the differences in flute shape, flute size, flute height, flute width, flute cross-sectional area, or filter media are regular and repeating.

49. An air filter media element for removing particulates from an air stream, the air filter media element comprising:

a) a first plurality of slots; and

b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of flutes exhibiting a difference in flute shape, flute size, flute height, flute width, flute length, flute cross-sectional area, or filter media relative to the first plurality of flutes;

wherein the first and second pluralities of flutes have a common upstream face and a common downstream face; and is

Wherein the first and second plurality of slots perform the following:

i) the pressure drop Δ P increases with increasing flow Q;

ii) prior to load, when testing the first and second plurality of slots independently and at the same speed, the first plurality of slots has an initial pressure drop Δ P over the second plurality of slots_2,0Low initial pressure drop Δ P_1,0；

ΔP_1,0<ΔP_2,0

iii) when tested in parallel, the velocity of the first plurality of flutes prior to load is greater than the average air filter element velocity prior to load and the velocity of the second plurality of flutes prior to load is less than the average air filter media element velocity prior to load;

V_1,0>V_{(element average), 0}

V_2,0<V_{(element average), 0}

iv) pressure drop difference Δ (Δ P) when tested in parallel₁) Equal to the speed Δ P of the first plurality of grooves_1,0,(V1,0)The pressure drop across the first plurality of flutes before the load tested minus the average velocity Δ P across the filter element_{1,0, (V element avg,0)}Pressure drop of the first plurality of slots prior to the load tested:

Δ(ΔP₁)＝ΔP_1,0,(V1,0)-ΔP_{1,0, (V element avg,0)}

v) pressure drop difference Δ (Δ P) for the second plurality of slots when tested in parallel₂) Equal to the speed Δ P of the second plurality of grooves_2,0,(V2,0)Pressure drop across the second plurality of flutes prior to the load tested minus the average filter element velocity Δ P_{2,0, (V element avg,0)}Pressure drop of the second plurality of slots prior to the load tested:

Δ(ΔP₂)＝ΔP_2,0,(V2,0)-ΔP_{2,0, (V element avg,0)}

vi)Δ(ΔP₁) And Δ (Δ P)₂) The sum is more than 0:

Δ(ΔP₁)+Δ(ΔP₂)<0

50. the air filter media element of any of claims 49 and 51-63, wherein the first plurality of flutes are arranged in a first plurality of layers of the fluted media and the second plurality of flutes are arranged in a second plurality of layers of the fluted media.

51. The air filtration media element of any of claims 49-50 and 52-63, wherein the first plurality of flutes constitute 10% to 90% of the volume of the media element and the second plurality of flutes constitute 90% to 10% of the volume of the media element.

52. The air filtration media element of any of claims 49-51 and 53-63, wherein the first plurality of flutes constitute 20-40% and the second plurality of flutes constitute 60-80% of the volume of the media element.

53. The air filtration media element of any of claims 49-52 and 54-63, wherein the first plurality of flutes constitute 40-60% and the second plurality of flutes constitute 60-40% of the volume of the media element.

54. The air filtration media element of any of claims 49-53 and 55-63, wherein the first plurality of flutes constitute between 10% and 90% of the media surface area of the media element and the second plurality of flutes constitute between 90% and 10% of the media surface area of the media element.

55. The air filtration media element of any of claims 49-54 and 56-63, wherein the first plurality of flutes constitute 20% to 40% and the second plurality of flutes constitute 60% to 80% of the media surface area of the media element.

56. The air filtration media element of any of claims 49-55 and 57-63, wherein the first plurality of flutes constitute 40-60% and the second plurality of flutes constitute 60-40% of the media surface area of the media element.

57. The air filtration media element of any of claims 49-56 and 58-63, wherein the first plurality of flutes constitute 10% to 90% of the inlet face of the media element and the second plurality of flutes constitute 90% to 10% of the inlet face of the media element.

58. The air filtration media element of any of claims 49-57 and 59-63, wherein the first plurality of flutes constitute 20% to 40% and the second plurality of flutes constitute 60% to 80% of the inlet face of the media element.

59. The air filtration media element of any of claims 49-58 and 60-63, wherein the first plurality of flutes constitute 40-60% and the second plurality of flutes constitute 60-40% of the inlet face of the media element.

60. The air filter media element of any of claims 49-59 and 61-63, further comprising a third plurality of flutes arranged in parallel flow with the first and second plurality of flutes;

wherein the first, second, and third pluralities of flutes exhibit differences in flute shape, flute size, flute height, flute width, flute length, flute cross-sectional area, or filter media.

61. The air filter media element of any of claims 49-60 and 62-63, wherein each of the first, second, and third pluralities of flutes are arranged in separate layers.

62. The air filter media element of any of claims 49-61 and 63, wherein the multilayer media is arranged in a rolled configuration or a stacked configuration.

63. The air filter media element of any of claims 49-62, wherein the differences in flute shape, flute size, flute height, flute width, flute cross-sectional area, or filter media are regular and repeating.

Technical Field

Embodiments herein relate to filter media, filter media packs, filter elements, air cleaners, and methods of making and using filter media, media packs, elements, and air cleaners. More particularly, embodiments herein relate to z-flow filtration media, media packs, and filter elements.

Background

Z-flow filtration media such as that described in U.S. patent No. 7,959,702 to inventor Rocklitz (Rocklitz) has multiple layers of media. Each layer has a fluted sheet, a facing sheet, and a plurality of flutes extending from the first face to the second face of the filter media element. A first portion of the plurality of flutes is closed to unfiltered air flowing into the first portion of the plurality of flutes, and a second portion of the plurality of flutes is closed to unfiltered air flowing out of the second portion of the plurality of flutes. Air entering the flutes on one face of the media element passes through the filter media before exiting the flutes on the other face of the media element.

Despite the many benefits of z-flow media, there remains a need for improved filtration performance, including filtration media, media packs, and elements having reduced pressure drop across the element and/or improved particulate loading capability.

Disclosure of Invention

The present application relates to filter media, filter media packs, filter elements, and air cleaners having two or more different media configurations, and methods of making and using the same. The different media configurations may be, for example, different slot geometries in z-flow filter media. The use of two or more different media configurations allows for improved performance, such as reduced pressure drop and/or increased load capacity, relative to the use of a single media configuration

In an exemplary implementation, two different media portions are combined into a single filter element, the two media portions having different pressure drop and load characteristics. The difference in pressure drop and load characteristics between media portions is typically less than the normal variation observed from manufacturing variations in the filter element, so the difference will typically be at least 5% for a particular measured and varied parameter, and more typically at least 10% for a particular measured and varied parameter.

In an exemplary configuration, the first media portion has a lower initial pressure drop than the second media portion, and the second media portion has a greater dust holding capacity than the first media portion. In some configurations, the combination of the two media portions results in an element with better performance than that achieved by a media element made from only one of the media alone and better performance than that achieved by averaging the performance of each media portion alone. Thus, a hybrid filter element may, for example, exhibit a reduced initial pressure drop, but also exhibit an increased load, relative to a media element made with only one media or the other.

An exemplary embodiment is an air filter element for removing particulates from an air stream, the air filter element comprising:

a) a first plurality of slots; and

b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of flutes exhibiting a difference in flute shape, flute size, flute height, flute width, flute length, flute cross-sectional area, or filter media relative to the first plurality of flutes;

wherein the first and second pluralities of slots have a common upstream face and a common downstream face; and is

Wherein, when loading the filter element with dust at a substantially constant speed, the first and second plurality of flutes perform the following:

a) the first and second pluralities of slots have substantially equal initial pressure drops from the upstream face to the downstream face;

b) the initial velocity of the first plurality of slots is greater than the initial velocity of the second plurality of slots;

c) during the dust load:

i) the pressure drops across the first and second pluralities of slots remain substantially equal relative to each other as the velocities of the first and second pluralities of slots vary relative to each other; and

ii) the velocity across the first plurality of slots decreases and the velocity across the second plurality of slots increases at least until the velocity across the second plurality of slots is greater than the velocity across the first plurality of slots.

In an embodiment, the transition from the velocity of the first plurality of slots being greater than the velocity of the second plurality of slots to the velocity of the second plurality of slots being greater than the velocity of the first plurality of slots occurs before the media element is loaded to 10% of the dust loading capacity.

In an embodiment, the transition from the velocity of the first plurality of slots being greater than the velocity of the second plurality of slots to the velocity of the second plurality of slots being greater than the velocity of the first plurality of slots occurs before the media element is loaded to 15% of the dust loading capacity.

In an embodiment, the transition from the velocity of the first plurality of slots being greater than the velocity of the second plurality of slots to the velocity of the second plurality of slots being greater than the velocity of the first plurality of slots occurs before the media element is loaded to 20% of the dust loading capacity.

The initial pressure drop refers to measuring a first portion of the media load, such as less than 1 inch of water, less than 2 inches of water, or less than 3 inches, 4 inches, or 5 inches of water. The initial pressure drop may also be measured, for example, when the element reaches a point of 1% of the maximum pressure drop, 2% of the maximum pressure drop, 5% of the maximum pressure drop, or 10% of the pressure drop.

For example, the slot heights may be varied such that each layer of media has a varying height, multiple layers of media have different heights, or larger portions of media have different heights.

The flow of the medium through these different layers and portions is typically a parallel flow. As used herein, the term "parallel" refers to a configuration in which the fluid stream to be filtered is dispersed into a first plurality of troughs and a second plurality of troughs and then typically reconverged. Thus, "parallel" does not require that the slots themselves be arranged in a geometrically parallel configuration (although they are often so arranged), but that the plurality of slots exhibit parallel flow with respect to one another. Thus, a "parallel" flow is in contrast to a "serial" flow (where in a serial flow, the flow comes from a first plurality of slots and then enters a second plurality of slots).

Structures made in accordance with the present disclosure may, for example, allow for improved pressure drop and dust loading relative to filter media elements and elements made from a single media type. In addition, in some implementations, more media can be added to a given volume without significantly increasing the initial pressure drop. In this way, a media structure can be produced that has a relatively low initial pressure drop while still having a relatively high dust loading capacity. This improvement can be obtained by combining a first media with a low initial pressure drop (but low dust loading capacity) with a second media with a higher initial pressure drop (and higher dust loading capacity). In some embodiments, the resulting combined media exhibits an initial pressure drop similar to the first media but with the dust loading of the second media.

The benefits of the mixed media structure can also be exploited to achieve more media in a given volume and to load more dust on a given media surface area. Thus, improved media performance can be achieved while having less media.

In an exemplary embodiment, an air filter element for removing particulates from an air stream includes: a) a first plurality of slots; and b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of flutes exhibiting a difference in flute shape, flute size, flute height, flute width, flute length, flute cross-sectional area, or filter media relative to the first plurality of flutes; wherein the first and second pluralities of slots have a common upstream face and a common downstream face; and wherein, when loading the filter element with dust at a substantially constant speed, the first and second plurality of flutes perform the following:

a) the first and second pluralities of slots have substantially equal initial pressure drops from the upstream face to the downstream face;

b) the initial velocity of the first plurality of slots is greater than the initial velocity of the second plurality of slots;

c) during the dust load, as shown in fig. 3A:

i) the pressure drops across the first and second pluralities of slots remain substantially equal relative to each other as the velocities of the first and second pluralities of slots vary relative to each other; and

ii) the velocity across the first plurality of slots decreases and the velocity across the second plurality of slots increases at least until the velocity across the second plurality of slots is greater than the velocity across the first plurality of slots.

In an exemplary implementation, an air filter media element for removing particulates from an air stream includes a) a first plurality of flutes; and b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of flutes exhibiting a difference in flute shape, flute size, flute height, flute width, flute cross-sectional area, flute length, or filter media relative to the first plurality of flutes; wherein the first and second pluralities of slots have a common upstream face and a common downstream face. When the filter element is loaded with dust, the first and second plurality of flutes will perform as follows:

a) the first plurality of slots have an initial pressure drop Δ Ρ over the second plurality of slots when the first and second plurality of slots are independently tested at the same media element velocity_2,iLow initial pressure drop Δ P_1,i(ii) a And an initial slope Δ (Δ P) of a pressure drop/load curve of the first plurality of slots at time a_1,i/L_1,i)_aGreater than an initial slope Δ (Δ P) of a pressure drop/load curve of the second plurality of slots_2,i/L_2,i)_a：

Δ(ΔP_1,i/L_1,i)_a>Δ(ΔP_2,i/L_2,i)_a

b) When the first plurality of groovesAnd the initial velocity V of the first plurality of slots at time a when the second plurality of slots are combined and tested simultaneously in parallel flow_1,aGreater than the initial velocity V of the second plurality of slots at time a_2,a：

V_1,a>V_2,a

c) Intermediate second velocities V of the first plurality of slots at subsequent times b when the first and second plurality of slots are combined and tested simultaneously in parallel flow_1,bEqual to the intermediate velocity V of the second plurality of grooves_2,b：

V_1,b＝V_2,b

d) A third velocity V of the first plurality of slots at a subsequent time c when the first and second plurality of slots are combined and tested simultaneously in parallel flow_1,cA third velocity V less than the second plurality of grooves_2,c：

V_1,c<V_2,c。

In an exemplary implementation, an air filter element for removing particulates from an air stream includes: a) a first plurality of slots; and b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of flutes exhibiting a difference in flute shape, flute size, flute height, flute width, flute cross-sectional area, flute length, or filter media relative to the first plurality of flutes; wherein the first and second pluralities of slots have a common upstream face and a common downstream face. When dust is simultaneously loaded under parallel flow conditions, and when the load reaches the point where the pressure drop of the media element is at least 10 inches of water, the first and second plurality of slots perform the following:

a) time-averaged velocity of the first plurality of slotsLess than the time-average velocity of the entire filter element And the time-average velocity of the second plurality of slotsGreater than the time average speed of the filter element

b) Load change Δ L of the first plurality of grooves₁Equal to the time-averaged velocity L in the first plurality of slots_{1,(V1 avg)}The load of the first plurality of slots measured below minus the time-averaged velocity L of the element_{1, (V element avg)}The following tested loads for the first plurality of slots:

ΔL_1＝L_{1,(V1 avg)}-L_{1, (V element avg)}

ΔL₁>0

c) Load change Δ L of the second plurality of grooves₂Equal to the time-averaged velocity L at the second plurality of slots_{2,(V2 avg)}The load of the second plurality of slots tested down minus the time-averaged velocity L of the element_{2, (V element avg)}The load of the second plurality of slots tested as follows:

ΔL_2＝L_{2,(V2 avg)}-L_{2, (V element avg)}

ΔL₂<0

d)ΔL₁And Δ L₂The sum is more than 0:

ΔL₁+ΔL₂>0。

in an exemplary implementation, a filter media element for removing particulates from an air stream includes: a) a first plurality of slots; and b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of flutes exhibiting a difference in flute shape, flute size, flute height, flute width, flute length, flute cross-sectional area, or filter media relative to the first plurality of flutes; wherein the first and second pluralities of slots have a common upstream face and a common downstream face; and wherein the first plurality of slots and the second plurality of slots perform the following:

i) the pressure drop Δ P increases with increasing flow Q;

ii) the first plurality of slots have an initial pressure drop Δ P over the second plurality of slots when the first and second plurality of slots are tested independently and at the same speed prior to load_2,0Low initial pressure drop Δ P_1,0；

ΔP_1,0<ΔP_2,0

iii) when tested in parallel, the velocity of the first plurality of flutes prior to load is greater than the average air filter element velocity prior to load and the velocity of the second plurality of flutes prior to load is less than the average air filter media element velocity prior to load;

V_1,0>V_{(element average), 0}

V_2,0<V_{(element average), 0}

v) pressure drop difference Δ (Δ P) when tested in parallel₁) Equal to the speed Δ P of the first plurality of grooves_1,0,(V1,0)The pressure drop across the first plurality of flutes prior to the load tested minus the average velocity Δ P across the filter element_{1,0, (V element avg,0)}Pressure drop of the first plurality of slots prior to the load tested:

Δ(ΔP₁)＝ΔP_1,0,(V1,0)-ΔP_{1,0, (V element avg,0)}

v) pressure drop difference Δ (Δ P) for the second plurality of slots when tested in parallel₂) Equal to the speed Δ P of the second plurality of grooves_2,0,(V2,0)The pressure drop across the second plurality of flutes prior to the load tested minus the average velocity Δ P across the filter element_{2,0, (V element avg,0)}Pressure drop of the second plurality of cells prior to the load tested:

Δ(ΔP₂)＝ΔP_2,0,(V2,0)-ΔP_{2,0, (V element avg,0)}

d)Δ(ΔP₁) And Δ (Δ P)₂) The sum is more than 0:

Δ(ΔP₁)+Δ(ΔP₂)<0。

in exemplary constructions, the first media element can comprise, for example, about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% (measured by volume of the enclosure) of the media element; and the second media element can comprise, for example, about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of the media element (measured in volume). As used herein, the enclosure volume means the total volume occupied by the media element when measuring the area contained within the perimeter of the bag. Thus, the enclosure volume may include the media itself, as well as the open upstream volume into which dust may be loaded and the downstream volume through which filtered air flows out of the media element. Alternatively, the first plurality of slots comprises 20% to 40% of the package volume and the second plurality of slots comprises 60% to 80% of the package volume. In other implementations, the first plurality of slots constitutes 40% to 60% of the package volume and the second plurality of slots constitutes 60% to 40% of the package volume. In yet another implementation, the first plurality of flutes comprise 60% to 90% of the inlet face of the media element and the second plurality of flutes comprise 40% to 10% of the package volume.

In such exemplary structures, the first media element can be, for example, about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% (measured as media surface area) of the media element; and the second media can be, for example, about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of the media element (measured as media surface area). As used herein, the packet surface area means the total surface area of the media in each media element with the media elements disassembled and the media stretched apart. . Alternatively, the first plurality of flutes constitute 20% to 40% of the media surface area and the second plurality of flutes constitute 60% to 80% of the media surface area. In other implementations, the first plurality of flutes constitute 40% to 60% of the inlet face of the media surface area and the second plurality of flutes constitute 60% to 40% of the media surface area pack. In yet another implementation, the first plurality of flutes constitute 60% to 90% of the media surface area and the second plurality of flutes constitute 40% to 10% of the media surface area. The media elements may also be characterized by the portion of the inlet face occupied by a particular media type. In some implementations, the first media element (including the first plurality of flutes) constitutes 10% to 90% of the inlet face of the media element, such as 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of the inlet face of the media element; and the second media element (including the second plurality of flutes) constitutes 90% to 10% of the inlet face of the media element, such as 90%, 80%, 70%, 60%, 50%, 40%, 30%, 20%, or 10% of the inlet face of the media element. Alternatively, the first plurality of flutes comprise 20% to 40% of the inlet face of the media element and the second plurality of flutes comprise 60% to 80% of the inlet face of the media element. In other implementations, the first plurality of flutes constitute 40% to 60% of the inlet face of the media element and the second plurality of flutes constitute 60% to 40% of the inlet face of the media element. In yet another implementation, the first plurality of flutes constitute 60% to 90% of the inlet face of the media element, and the second plurality of flutes constitute 40% to 10% of the inlet face of the media element.

Another embodiment of the filter media element comprises a third plurality of flutes arranged in parallel flow with the first and second plurality of flutes; wherein the first, second, and third pluralities of flutes exhibit regularly repeating differences in flute shape, flute size, flute height, flute width, flute cross-sectional area, taper, or filter media. Optionally, each of the first, second and third pluralities of slots are arranged in separate pluralities of layers. It should be understood that in some implementations, more than three of the plurality of flutes are arranged in parallel flow, wherein each of the plurality of flutes exhibit differences in flute shape, flute size, flute height, flute width, flute cross-sectional area, or filter media. Typically, these differences in slot characteristics are repetitive, often regularly repetitive.

In an exemplary structure having three types of flutes, the first flute, the second flute, and the third flute may be selected such that the first plurality of flutes constitute 20% to 50% of the volume of the dielectric element, such as 20%, 30%, 40%, or 50% of the volume of the dielectric element; the second plurality of flutes constitute 20% to 50% of the volume of the pack, such as 20%, 30%, 40%, or 50% of the volume of the media element; and the third plurality of flutes constitutes 20% to 50% of the volume of the dielectric element, such as 20%, 30%, 40% or 50% of the volume of the dielectric element.

In an exemplary structure having three types of flutes, the first flute, the second flute, and the third flute may be selected such that the first plurality of flutes constitute 20% to 50% of the media surface area of the media element, such as 20%, 30%, 40%, or 50% of the media surface area of the filter media element; the second plurality of flutes constitute 20% to 50% of the media surface area of the media element, such as 20%, 30%, 40%, or 50% of the media surface area of the media element; and the third plurality of flutes constitute 20% to 50% of the media surface area of the media element, such as 20%, 30%, 40%, or 50% of the surface area of the media element.

In an exemplary configuration having three types of flutes, the first flute, the second flute, and the third flute may be selected such that the first plurality of flutes constitute 20% to 50% of the inlet face of the media element, such as 20%, 30%, 40%, or 50% of the inlet face of the filter media element; the second plurality of flutes comprise 20% to 50% of the inlet face of the media element, such as 20%, 30%, 40%, or 50% of the inlet face of the filter media element; and the third plurality of flutes constitute 20% to 50% of the inlet face of the media element, such as 20%, 30%, 40%, or 50% of the inlet face of the media element.

An exemplary air filter media element has multiple layers of fluted z-flow media. In some constructions, each layer of media has a facing sheet and a fluted sheet. Each fluted sheet includes a plurality of flutes that exhibit regularly repeating differences in flute shape, flute size, flute height, flute width, flute cross-sectional area, or filter media. The plurality of slots are arranged in a parallel flow pattern. The facing sheet may, for example, be composed of the same material that forms the fluted sheet, or may be composed of a different material. The facing sheet is typically not grooved, but may be grooved in some constructions. The facing sheet may have filtering properties or be a non-filtering material (such as a spacer material) that does not have filtering properties. Additionally, the facing sheet may cover all or only a portion of each fluted sheet. The facing sheet may be continuous or segmented such that individual facing sheet segments are positioned against each facing sheet.

The different media types in the plurality of flutes are in parallel flow with each other. As described above, the term "parallel" as used herein refers to a configuration in which the fluid streams to be filtered are dispersed into a first plurality of troughs and a second plurality of troughs and then typically converge again. Thus, "parallel" does not require that the slots themselves be arranged in a geometrically parallel configuration (although they are often so arranged), but that the plurality of slots have a generally parallel flow with respect to each other. Thus, a "parallel" flow is in contrast to a "serial" flow, where the flow comes from a first plurality of slots and then enters a second plurality of slots. It should be understood that in some constructions, such as wrap constructions, the fluid flow may be between adjacent portions of the filter media.

Further, it will be understood that parallel flow may include media elements, wherein the plurality of slots and the second plurality of slots have the same slot length or different slot lengths so long as parallel flow is present. Similarly, the first and second plurality of slots may have a single front face and a single back face, may have front and back faces that are flush with one another, or may have front and back faces that are offset from one another. In some configurations, the first and second pluralities of slots are separate from each other but still in parallel flow, thus functioning as a single element.

The media may be arranged in various configurations within the media element, including alternating single-sided layers (e.g., configurations a/B/C/a/B/C., where A, B and C each refer to a different slot type, and "/" refers to separate layers.

The use of the terms "a", "B" and "C" slots is meant to represent media having different characteristics. For example, the a-groove may have a higher height than the B-groove or the C-groove; or the B-shaped groove can have a larger or smaller width than the A-shaped groove or the C-shaped groove; or the a-grooves may be formed of a media having a higher efficiency and/or permeability than the B-grooves or the C-grooves.

It should also be understood that the media may be arranged in a structure in which slot-like layers are grouped together, such as a media element having the structure a/B/C. In this configuration, there are four layers with a slots, three layers with B slots, and three layers with C slots. Each of the layers of the type having slots A, B and C are grouped together. Different media regions containing different types of slots may be in direct contact with one another, such as by being arranged in a stacked or wrapped configuration. They are also arranged so that different media regions are separated by partitions or other components.

It will also be appreciated that similar slots of more than three or four layers may be grouped together depending on slot size, media element size, etc. The media element may be constructed with multiple layers of each media, such as, for example, ten, twenty, thirty, or forty layer grouped a slots; or ten, twenty, thirty, or forty layer grouped B slots, etc.

In some configurations, the grooves may vary repeatedly within a layer and between layers. For example, a dielectric element having the structure abc./def./C./def.. alternates layers having repeating grooves a, B, and C with layers having grooves D, E, and F. Other examples are not limited to including a media element having an ab./cdef./ab./CDEF; a media element having a./bcd./a./bcd.

The use of more than one slot configuration within a given filter media element or air cleaner may provide various benefits, including having a lower initial limit of one slot configuration and dust holding capacity of a second slot configuration. Thus, an element formed from the combined media may outperform an element formed from only one slot configuration. Combining different types and styles of slot geometries in this manner allows for improvements in one or more of cost, initial pressure drop, load capacity, or other aspects of filtration performance.

In some configurations, the relative position of the media is determined by the desired characteristics of the elements. For example, due to the air cleaner in which the filter element is placed, a higher permeability media may be arranged in the region of the filter element with the highest head-on velocity to reduce the initial restriction. In other embodiments, a higher efficiency media is arranged in the region with the highest head-on velocity to increase the initial efficiency of the filter element.

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 can be found in the detailed description and the appended claims. Other aspects will become apparent to those skilled in the art upon reading and understanding the following detailed description and viewing the drawings that form a part hereof, and are not to be considered in a limiting sense. The scope herein is defined by the appended claims and their legal equivalents.

Drawings

Various aspects may be more completely understood in conjunction with the following drawings, in which:

FIG. 1 is a perspective view of an exemplary filter element according to an exemplary embodiment.

Fig. 2A is an enlarged schematic cross-sectional view of a cross-section of a filter media.

FIG. 2B is an enlarged partial cross-sectional view of a sheet of fluted medium and top and bottom facing sheets.

FIGS. 3A-3F are schematic representations of component performance (these figures are representative and not based on actual measured test data)

FIG. 4A is a top schematic view of an exemplary filter media element, showing a coiled configuration with two types of filter media.

FIG. 4B is a top schematic view of an exemplary filter media element, showing a coiled configuration with three types of filter media.

FIG. 5 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration of filter media.

FIG. 6 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration of filter media.

FIG. 7 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration of filter media.

FIG. 8 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration with three types of filter media.

FIG. 9 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration with two types of filter media.

FIG. 10 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration with two types of filter media.

FIG. 11 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration with two types of filter media.

FIG. 12 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration with two types of filter media.

FIG. 13 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration with two types of filter media.

FIG. 14 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration with three types of filter media.

FIG. 15 is a top schematic view of an exemplary filter media element, showing a coiled configuration with two types of filter media.

FIG. 16 is a top schematic view of an exemplary filter media element, showing a coiled configuration with three types of filter media.

FIG. 17 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration with three types of filter media.

FIG. 18 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration with two types of filter media.

FIG. 19 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration with two types of filter media.

FIG. 20 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration with two types of filter media.

FIG. 21 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration with two types of filter media.

FIG. 22 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration with two types of filter media.

FIG. 23 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration with three types of filter media.

FIG. 24A is a top schematic view of an exemplary filter media element, showing a coiled configuration with two types of filter media.

FIG. 24B is a top schematic view of an exemplary filter media element, showing a coiled configuration with two types of filter media.

FIG. 25A is a top schematic view of an exemplary filter media element, showing a coiled configuration with three types of filter media.

FIG. 25B is a top schematic view of an exemplary filter media element, showing a coiled configuration with three types of filter media.

FIG. 26A is a top schematic view of an exemplary filter media element, showing a coiled configuration with two types of filter media.

FIG. 26B is a top schematic view of an exemplary filter media element, showing a coiled configuration with two types of filter media.

Fig. 27 shows performance results of comparative testing of filter elements having different media types.

FIGS. 28A and 28B show performance results for various media constructions, including dust loading and pressure drop

FIGS. 29A and 29B show performance results for various media constructions, including dust loading and pressure drop

FIGS. 30A and 30B show performance results for various media constructions, including dust loading and pressure drop

While the 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. It should be understood, however, that the scope of this document is not limited to the described embodiments. On the contrary, the invention is to cover modifications, equivalents, and alternatives falling within the spirit and scope of the invention.

Detailed Description

In an exemplary embodiment, the present application relates to an air filtration media element comprising a plurality of layers of fluted media, each layer comprising a first plurality of flutes and a second plurality of flutes, the first plurality of flutes and the second plurality of flutes arranged in a parallel flow configuration; wherein the first and second plurality of flutes exhibit differences in flute shape, flute size, flute height, flute width, flute length, flute cross-sectional area, or filter media. In an exemplary embodiment, the difference is a difference in taper of the first and second plurality of slots.

These multiple slots are arranged in parallel flow. As noted above, as used in this context, the term "parallel" refers to a configuration in which the fluid streams to be filtered are dispersed into a first plurality of troughs and a second plurality of troughs and then typically converge again. Thus, "parallel" does not require that the slots themselves be arranged in a geometrically parallel configuration (although they are often so arranged), but that the plurality of slots exhibit parallel flow with respect to one another. Thus, a "parallel" flow is in contrast to a "serial" flow (where in a serial flow, the flow comes from a first plurality of slots and then enters a second plurality of slots).

In some implementations, the filter media element can be configured such that the first and second pluralities of flutes are arranged together within at least one layer of fluted media. In other implementations, the first plurality of slots is arranged in a first plurality of layers and the second plurality of slots is arranged in a second plurality of layers of fluted media. The two structures may also be combined such that each layer has repeated differences between the slots and different layers are combined.

An exemplary embodiment is an air filter element for removing particulates from an air stream, the air filter element comprising:

a) a first plurality of slots; and

b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of flutes exhibiting a difference in flute shape, flute size, flute height, flute width, flute length, flute cross-sectional area, or filter media relative to the first plurality of flutes;

wherein the first and second pluralities of slots have a common upstream face and a common downstream face; and is

Wherein, when loading the filter element with dust at a substantially constant speed, the first and second plurality of flutes perform the following:

a) the first and second pluralities of slots have substantially equal initial pressure drops from the upstream face to the downstream face;

b) the initial velocity of the first plurality of slots is greater than the initial velocity of the second plurality of slots;

c) during the dust load:

i) the pressure drops across the first and second pluralities of slots remain substantially equal relative to each other as the velocities of the first and second pluralities of slots vary relative to each other; and

ii) the velocity across the first plurality of slots decreases and the velocity across the second plurality of slots increases at least until the velocity across the second plurality of slots is greater than the velocity across the first plurality of slots.

In an embodiment, the transition from the velocity of the first plurality of slots being greater than the velocity of the second plurality of slots to the velocity of the second plurality of slots being greater than the velocity of the first plurality of slots occurs before the media element is loaded to 10% of the dust loading capacity.

In an embodiment, the transition from the velocity of the first plurality of slots being greater than the velocity of the second plurality of slots to the velocity of the second plurality of slots being greater than the velocity of the first plurality of slots occurs before the media element is loaded to 15% of the dust loading capacity.

In an embodiment, the transition from the velocity of the first plurality of slots being greater than the velocity of the second plurality of slots to the velocity of the second plurality of slots being greater than the velocity of the first plurality of slots occurs before the media element is loaded to 20% of the dust loading capacity.

In an exemplary implementation, two different media elements are combined into a single filter element, the two media elements having different pressure drop and load characteristics. In an example, the first media element has a lower initial pressure drop than the second media element, and the second media element has a greater dust holding capacity than the first media element. In some configurations, the combination of these two media results in an element with better performance than achieved with either media alone and better performance than achieved by averaging the performance of each media element alone. Thus, the hybrid filter element may, for example, exhibit a reduced initial pressure flow, but also exhibit an increased load.

In an exemplary implementation, an air filter media element for removing particulates from an air stream includes: a first plurality of slots; and a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of flutes exhibit differences in flute shape, flute size, flute height, flute width, flute length, flute cross-sectional area, or filter media relative to the first plurality of flutes. The first and second pluralities of grooves have a common upstream face and a common downstream face; and when loaded with dust at a substantially constant velocity, the first and second plurality of slots perform the following: a) the first and second pluralities of slots have substantially equal initial pressure drops from the upstream face to the downstream face; b) the initial velocity of the first plurality of slots is greater than the initial velocity of the second plurality of slots; c) during the dust load: i) the velocity through the first plurality of slots decreases and the velocity through the second plurality of slots increases at least until the velocity through the second plurality of slots is greater than the velocity through the first plurality of slots; and ii) the pressure drops across the first and second pluralities of slots remain substantially equal relative to each other as the velocities of the first and second pluralities of slots vary relative to each other.

Velocity is the volumetric flow rate/element volume. An example range of speeds is, for example, from 300 to 3000 cfm/cubic foot. In some implementations, the speed ranges from 500 to 2000 cfm/cubic foot. In certain embodiments, the velocity is greater than 300 cfm/cubic foot, greater than 500 cfm/cubic foot, greater than 1000 cfm/cubic foot, or greater than 2000 cfm/cubic foot. In certain embodiments, the velocity is less than 3000 cfm/cubic foot, less than 2000 cfm/cubic foot, less than 1000 cfm/cubic foot, or less than 500 cfm/cubic foot.

The flow through the element may be, for example, 200 to 3000 cubic feet per minute (cfm). In some implementations, the flow is greater than 200cfm, greater than 500cfm, greater than 1000cfm, greater than 1500cfm, greater than 2000cfm, or greater than 2500 cfm. In some implementations, the flow is less than 3000cfm, less than 2500cfm, less than 2000cfm, less than 1500cfm, less than 1000cfm, or less than 500 cfm.

The restriction at the terminal end of the element may be, for example, 10 to 40 inches of water. In some implementations, the restriction at the terminal is greater than 10 inches of water, greater than 15 inches of water, greater than 20 inches of water, greater than 25 inches of water, greater than 30 inches of water, or greater than 35 inches of water. In some implementations, the restriction at the terminal is less than 40 inches of water, less than 35 inches of water, less than 30 inches of water, less than 25 inches of water, less than 20 inches of water, or less than 15 inches of water.

The limit rise to the terminal may be, for example, 5 to 35 inches of water. In some implementations, the limited rise to the terminal can be greater than 5 inches of water, greater than 10 inches of water, greater than 15 inches of water, greater than 20 inches of water, greater than 25 inches of water, greater than 30 inches of water, or greater than 35 inches of water. In some implementations, the limit to the terminal rises less than 40 inches of water, less than 35 inches of water, less than 30 inches of water, less than 25 inches of water, less than 20 inches of water, or less than 15 inches of water.

In exemplary constructions, the first media element can be, for example, about 20%, 30%, 40%, or 50% of the media element (measured in volume); and the second media element can be, for example, about 20%, 30%, 40%, or 50% of the media element (measured in volume). As used herein, the enclosure volume means the total volume occupied by the media element when measuring the area contained within the perimeter of the bag. Thus, the enclosure volume can include the media itself, as well as the open volume into which the dust can be loaded.

In such exemplary structures, the first media element can be, for example, about 20%, 30%, 40%, or 50% of the media element (measured as media surface area); and the second media element can be, for example, about 20%, 30%, 40%, or 50% of the media element (measured as media surface area). As used herein, the packet surface area means the total surface area of the media in each media element with the media elements disassembled and the media stretched apart.

In some implementations, the first plurality of flutes constitute from 10% to 90% of the inlet face of the media element, and the second plurality of flutes constitute from 90% to 10% of the inlet face of the media element. Alternatively, the first plurality of flutes comprise 20% to 40% of the inlet face of the media element and the second plurality of flutes comprise 60% to 80% of the inlet face of the media element. In other implementations, the first plurality of flutes constitute 40% to 60% of the inlet face of the media element and the second plurality of flutes constitute 60% to 40% of the inlet face of the media element. In yet another implementation, the first plurality of flutes constitute 60% to 90% of the inlet face of the media element, and the second plurality of flutes constitute 40% to 10% of the inlet face of the media element.

Another embodiment of the filter media element comprises a third plurality of flutes arranged in parallel flow with the first and second plurality of flutes; wherein the first, second, and third pluralities of flutes exhibit regularly repeating differences in flute shape, flute size, flute height, flute width, flute cross-sectional area, or filter media. Optionally, each of the first, second and third pluralities of slots are arranged in separate pluralities of layers. It should be understood that in some implementations, a plurality of slots greater than three are arranged in parallel flow, wherein each of the plurality of slots exhibits regular repeating differences in slot shape, slot size, slot height, slot width, slot cross-sectional area, or filter media.

In an exemplary configuration having three types of flutes, the first flute, the second flute, and the third flute may be selected such that the first plurality of flutes comprise 30% to 50% of the inlet face of the media element; the second plurality of flutes comprise 20% to 40% of the inlet face of the media element; and the third plurality of flutes comprise 20% to 40% of the inlet face of the media element.

In another exemplary structure having three types of flutes, the first flute, the second flute, and the third flute may be selected such that the first plurality of flutes comprise 50% to 70% of the inlet face of the media element; the second plurality of flutes comprise 10% to 30% of the inlet face of the media element; and the third plurality of flutes comprise 10% to 30% of the inlet face of the media element.

In some implementations, the multiple layers of single facer media are arranged in a rolled configuration, while in other implementations, the facer media are arranged in a stacked configuration.

In some configurations, the first and second pluralities of single facer media are arranged in a hybrid configuration, wherein the one or more layers of the first plurality of single facer media alternate with the one or more layers of the second plurality of single facer media. In an exemplary implementation having at least three types of single facer media, the first and second plurality of layers of single facer media are arranged in a hybrid configuration, wherein the one or more layers of the first plurality of single facer media alternate with the one or more layers of the second plurality of single facer media and the one or more layers of the third plurality of single facer media. Additionally, when three types of media are used, the first, second, and third pluralities of single facer media are arranged in a hybrid configuration, wherein the one or more layers of the first plurality of single facer media alternate with the one or more layers of the second plurality of single facer media and the one or more layers of the third plurality of single facer media. In some implementations, more than three types of filter media are used, and these different types of media may be combined in a mixed manner or in a polymerized manner, where the different types of media are collected together without mixing between media types. Alternatively, the media may be aggregated into smaller groups and then mixed, such as by one media having five layers and a different media having three layers.

Referring now to the drawings, filter media, media elements, and other aspects of the elements will be identified.

First, with respect to FIG. 1, a perspective view of an exemplary filter element 10 is shown. The exemplary filter element 10 includes an inlet 12, an outlet 14 on a side of the element 10 opposite the inlet 12, and a coiled z-flow media 20 within the element 10. A seal is shown surrounding the inlet 12 and a support frame 40 is depicted. It should also be understood that the filter element may have a reverse flow to that shown in fig. 1, such that the inlet 12 and outlet 14 are reversed.

Fig. 2A is an enlarged schematic cross-sectional view of a cross-section of a single facer filter media 200 suitable for use with filter media elements and filter elements as described herein. The single facer media 200 includes a fluted sheet 210, and a top facing sheet 220 and a bottom facing sheet 230. The fluted sheet 210 includes a plurality of flutes 250. A fluid stream to be filtered (such as air for an internal combustion engine) enters the slots 250 along a flow path 260 and then travels along the slots until passing through the filter media and out of the different slots along a fluid flow path 270. Such fluid flow through fluted media elements is described, for example, in U.S. patent No. 7,99,702 to Rocklitz, which is incorporated herein by reference in its entirety.

Fig. 2B is an enlarged front view of a sheet of fluted media having a fluted sheet 280, a top facing sheet 282, and a facing media 284 constructed and arranged in accordance with an embodiment of the invention, illustrating example flute dimensions. Grooved sheet 280 includes grooves 281. In the depicted embodiment, the slot 281 has a width A measured from a first peak to an adjacent peak. In an exemplary embodiment, the width a is 0.75 to 0.125 inches, alternatively 0.5 to 0.25 inches, and alternatively 0.45 to 0.3 inches. The slot 281 also has a height B measured from adjacent peaks of the same size. The slot 281 has an area between the slotted sheet 281 and the facing sheet 282 measured perpendicular to the slot length. The area may vary depending on the length of the slot as the height, width or shape of the slot varies along its length, such as when the slot is tapered.

In an exemplary embodiment, an air filter element for removing particulates from an air stream includes: a) a first plurality of slots; and b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of flutes exhibiting a difference in flute shape, flute size, flute height, flute width, flute length, flute cross-sectional area, or filter media relative to the first plurality of flutes; wherein the first and second pluralities of slots have a common upstream face and a common downstream face; and wherein, when loading the filter element with dust at a substantially constant speed, the first and second plurality of flutes perform the following:

a) the first and second pluralities of slots have substantially equal initial pressure drops from the upstream face to the downstream face;

b) the initial velocity of the first plurality of slots is greater than the initial velocity of the second plurality of slots;

c) during the dust load, as shown in fig. 3A:

i) the pressure drops across the first and second pluralities of slots remain substantially equal relative to each other as the velocities of the first and second pluralities of slots vary relative to each other; and

ii) the velocity across the first plurality of slots decreases and the velocity across the second plurality of slots increases at least until the velocity across the second plurality of slots is greater than the velocity across the first plurality of slots.

These properties are shown, for example, in fig. 3A, which is a schematic representation of the flow variation in the element (which is representative and not based on actual measured test data).

In an exemplary implementation, an air filter media element for removing particulates from an air stream includes: a) a first plurality of slots; and b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of flutes exhibiting a difference in flute shape, flute size, flute height, flute width, flute cross-sectional area, flute length, or filter media relative to the first plurality of flutes; wherein the first and second pluralities of slots have a common upstream face and a common downstream face. When the filter element is loaded with dust, the first and second plurality of flutes will perform as follows:

a) the first plurality of slots have an initial pressure drop Δ Ρ over the second plurality of slots when the first and second plurality of slots are independently tested at the same media element velocity_2,iLow initial pointInitial pressure drop Δ P_1,i(ii) a And an initial slope Δ (Δ P) of a pressure drop/load curve of the first plurality of slots at time a_1,i/L_1,i)_aGreater than an initial slope Δ (Δ P) of a pressure drop/load curve of the second plurality of slots_2,i/L_2,i)_a：

Δ(ΔP_1,i/L_1,i)_a>Δ(ΔP_2,i/L_2,i)_a

b) Initial velocity V of the first plurality of slots at time a when the first and second plurality of slots are combined and tested simultaneously in parallel flow_1,aGreater than the initial velocity V of the second plurality of slots at time a_2,a：

V_1,a>V_2,a

c) Intermediate second velocities V of the first plurality of slots at subsequent times b when the first and second plurality of slots are combined and tested simultaneously in parallel flow_1,bEqual to the intermediate velocity V of the second plurality of grooves_2,b：

V_1,b＝V_2,b

d) A third velocity V of the first plurality of slots at a subsequent time c when the first and second plurality of slots are combined and tested simultaneously in parallel flow_1,cA third velocity V less than the second plurality of grooves_2,c：

V_1,c<V_2,c

These properties are shown, for example, in fig. 3B and 3C, which are schematic representations of the performance of the element (which are representative, not based on actual measured test data).

In an exemplary implementation, an air filter element for removing particulates from an air stream includes: a) a first plurality of slots; and b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of flutes exhibiting a difference in flute shape, flute size, flute height, flute width, flute cross-sectional area, flute length, or filter media relative to the first plurality of flutes; wherein the first and second pluralities of slots have a common upstream face and a common downstream face. When dust is simultaneously loaded under parallel flow conditions, and when the load reaches the point where the pressure drop of the media element is at least 10 inches of water, the first and second plurality of slots perform the following:

a) time-averaged velocity of the first plurality of slotsLess than the time-average velocity of the entire filter element And the time-average velocity of the second plurality of slotsGreater than the time average speed of the filter element

b) Load change Δ L of the first plurality of grooves₁Equal to the time-averaged velocity L in the first plurality of slots_{1,(V1 avg)}The load of the first plurality of slots measured below minus the time-averaged velocity L of the element_{1, (V element avg)}The following tested loads for the first plurality of slots:

ΔL₁＝L_{1,(V1 avg)}-L_{1, (V element avg)}

ΔL₁>0

c) Load change Δ L of the second plurality of grooves₂Equal to the time-averaged velocity L at the second plurality of slots_{2,(V2 avg)}The load of the second plurality of slots tested down minus the time-averaged velocity L of the element_{2, (V element avg)}The load of the second plurality of slots tested as follows:

ΔL₂＝L_{2,(V2 avg)}-L_{2, (V element avg)}

ΔL₂<0

d)ΔL₁And Δ L₂The sum is more than 0:

ΔL₁+ΔL₂>0

these properties are shown, for example, in fig. 3D and 3E, which are schematic representations of the performance of the element (which are representative, not based on actual measured test data).

In an exemplary implementation, a filter media element for removing particulates from an air stream includes: a) a first plurality of slots; and b) a second plurality of slots arranged in a parallel flow configuration with the first plurality of slots; the second plurality of flutes exhibiting a difference in flute shape, flute size, flute height, flute width, flute length, flute cross-sectional area, or filter media relative to the first plurality of flutes; wherein the first and second pluralities of slots have a common upstream face and a common downstream face; and wherein the first plurality of slots and the second plurality of slots perform the following:

i) the pressure drop Δ P increases with increasing flow Q;

ii) the first plurality of slots have an initial pressure drop Δ P over the second plurality of slots when the first and second plurality of slots are tested independently and at the same speed prior to load_2,0Low initial pressure drop Δ P_1,0；

ΔP_1,0<ΔP_2,0

iii) when tested in parallel, the velocity of the first plurality of flutes prior to load is greater than the average air filter element velocity prior to load and the velocity of the second plurality of flutes prior to load is less than the average air filter media element velocity prior to load;

V_1,0>V_{(element average), 0}

V_2,0<V_{(element average), 0}

v) pressure drop difference Δ (Δ P) when tested in parallel₁) Equal to the speed Δ P of the first plurality of grooves_1,0,(V1,0)The pressure drop across the first plurality of flutes prior to the load tested minus the average velocity Δ P across the filter element_{1,0, (V element avg,0)}Pressure drop of the first plurality of slots prior to the load tested:

Δ(ΔP₁)＝ΔP_1,0,(V1,0)-ΔP_{1,0, (V element avg,0)}

v) pressure drop difference Δ (Δ P) for the second plurality of slots when tested in parallel₂) Equal to the speed Δ P of the second plurality of grooves_2,0,(V2,0)The pressure drop across the second plurality of flutes prior to the load tested minus the average velocity Δ P across the filter element_{2,0, (V element avg,0)}Pressure drop of the second plurality of cells prior to the load tested:

Δ(ΔP₂)＝ΔP_2,0,(V2,0)-ΔP_{2,0, (V element avg,0)}

d)Δ(ΔP₁) And Δ (Δ P)₂) The sum is more than 0:

Δ(ΔP₁)+Δ(ΔP₂)<0。

these properties are shown, for example, in fig. 3F, which is a schematic representation of performance (which is representative and not based on actual measured test data).

Fig. 4A is a top schematic view of an exemplary filter media element 300 for use in a filter element. The filter media element 300 has two types of filter media: a first medium 310 and a second medium 320. The media is shown in a coiled configuration, where the two types of filter media are mixed and overlapped. The filter media 310 and 320 are shown in schematic form without the actual flutes of the media. The filter media element 300 can typically be formed by simultaneously winding different types of media around a central axis. In this exemplary embodiment, the ratio of the surface areas of media 310 to 320 is about 1: 1.

FIG. 4B is a top schematic view of an exemplary filter media element 400, showing a coiled configuration with three types of filter media. The filter media element 400 has three types of filter media: a first medium 410, a second medium 420, and a third medium 430. The media is shown in a coiled configuration, where three types of filter media are mixed and overlapped. The filter media 410, 420, and 430 are shown in schematic form, without the actual flutes of the media. The filter media element 430 may typically be formed by simultaneously winding three different types of media around a central axis. In this exemplary embodiment, the ratio of the surface areas of media 410 and 420 and 430 is about 1:1: 1.

FIG. 5 is a top schematic view of an exemplary filter media element 500, showing a stacked configuration with two types of flutes. The filter media element 500 has two types of flutes: a first groove 510 and a second groove 520.

FIG. 6 is a top schematic view of an exemplary filter media element 600 illustrating a stacked configuration with different types of filter media. The filter media element 600 has three types of flutes: a first slot 610, a second slot 620, and a third slot 630.

FIG. 7 is a top schematic view of an exemplary filter media element 700 showing a stacked configuration with different types of flutes. The filter media element 710 has two types of flutes: a first slot 710 and a second slot 720. FIG. 8 is a top schematic view of an exemplary filter media element 800, illustrating a stacked configuration with three types of filter media. The three types of filter media are first media 810, second media 820, and third media 830. The media is shown in a stacked configuration, with three types of filter media separated by media type without mixing. In this exemplary embodiment, the ratio of filter media 810 to 820 and 830 is approximately 4:3:3 based on the packet entry area. FIG. 9 is a top schematic view of an exemplary filter media element 900, showing a stacked configuration with two types of filter media: a first medium 910 and a second medium 920. The media is shown in a stacked configuration, where the two types of filter media are separated without mixing. In this exemplary embodiment, the ratio of filter media 910 to 920 is approximately 1:1 based on the total packet entry area. FIG. 10 is a top schematic view of an exemplary filter media element 1000, showing a stacked configuration with two types of filter media: a first media 1010 and a second media 1020. The media is shown in a stacked configuration. In this exemplary embodiment, the ratio of filter media 1010 to 1020 is approximately 9:1 based on the total packet entry area.

FIG. 11 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration with two types of filter media. The filter media element 1100 has two types of filter media: a first medium 1110 and a second medium 1120. Media 1110 and 1120 are stacked with five layers of filter media 1110 alternating with two layers of media 1120. FIG. 12 is a top schematic view of an exemplary filter media element, illustrating a stacked configuration with two types of filter media. The filter media element 1200 has two types of filter media: a first medium 1210 and a second medium 1220. The media is shown in a stacked configuration. The media 1210 and 1220 are stacked with two layers of filter media 1210 alternating with one layer of media 1220. Fig. 13 is a top schematic view of an exemplary filter media element 1300, showing a stacked configuration with two types of filter media. The filter media element 1300 has two types of filter media: a first medium 1310 and a second medium 1320. Media 1310 and 1320 are stacked, with one layer of filter media 1310 alternating with one layer of media 1320. Fig. 14 is a top schematic view of an exemplary filter media element 1400. The filter media element 1400 has three types of filter media: first medium 1410, second medium 1420, and third medium 1430. Dielectric layers 1410, 1420, and 1430 are arranged in alternating stacks. Fig. 15 is a top schematic view of an exemplary filter media element 1500, showing a coiled configuration with two types of filter media 1510 and 1520. The media is rolled with the first media 1510 on the inside and the second media 1520 on the outside, the first media 1510 and the second media 1520 spliced together.

FIG. 16 is a top schematic view of an exemplary filter media element 1600, showing a coiled configuration with three types of filter media 1610, 1620, and 1630. The media is rolled with the first media 1610 on the inside, the second media 1620 in the middle, and the third media 1630 on the outside. The first medium 1610 and the second medium 1620 are spliced together, and the second medium 1620 and the third medium 1630 are spliced together.

FIG. 17 is a top partially schematic view of an exemplary filter media element 1700 showing a stacked configuration with three types of filter media. The three types of filter media are a first media 1710, a second media 1720, and a third media 1730. The media is shown in a stacked configuration, with three types of filter media separated by media type without mixing. In this exemplary embodiment, the ratio of filter media 1710 to 1720 and 1730 is approximately 4:3:3 based on the total packet entry area.

FIG. 18 is a top schematic view of an exemplary filter media element 1800 showing a stacked configuration with two types of filter media: a first medium 1810 and a second medium 1820. The media is shown in a stacked configuration, with two types of filter media separated. In this exemplary embodiment, the ratio of filter media 1810 to 1820 is approximately 1:1 based on the total packet entry area.

FIG. 19 is a top schematic view of an exemplary filter media element 1900 showing a stacked configuration with two types of filter media. Filter media element 1900 has two types of filter media: a first medium 1910 and a second medium 1920. The media is shown in a stacked configuration. In this exemplary embodiment, the ratio of filter media 1910 to 1920 is approximately 9:1 based on the total packet entry area.

FIG. 20 is a top schematic view of an exemplary filter media element 2000, illustrating a stacked configuration with two types of filter media. The filter media element 2000 has two types of filter media: a first medium 2010 and a second medium 2020. The media element 2000 has six layers of filter media 2010 alternating with two layers of media 2020.

FIG. 21 is a top schematic view of an exemplary filter media element 2100, illustrating a stacked configuration with two types of filter media. The filter media element 2100 has two types of filter media: a first medium 2110 and a second medium 2120. The media element 2100 has two layers of filter media 2110 alternating with one layer of media 2120.

FIG. 22 is a top partially schematic view of an exemplary filter media element 2200, illustrating a stacked configuration with two types of filter media. The two types of filter media are first media 2210 and second media 2220. The media is shown in a stacked configuration, where the two types of filter media are mixed.

FIG. 23 is a top partially schematic view of an exemplary filter media element 2300, showing a stacked configuration with three types of filter media. The three types of filter media are first media 2310, second media 2320, and third media 2330. The media is shown in a stacked configuration, with three types of filter media mixed.

Fig. 24A is a top schematic view of an exemplary filter media element 2400, showing a coiled configuration with two types of filter media: a first media 2410 and a second media 2420. The media is shown in a rolled configuration, where the two types of media are distinguished from each other by laying down the filter media 2420 first and then laying down the filter media 2420 second. In this exemplary embodiment, the ratio of packet entry areas 2420 to 2410 is about 2: 1. This structure can be created by: for example, winding a first single facer media type over a period of time; cutting the roll and splicing the second single facer media type to an end region of the first single facer media type; continuing the winding process; and repeated as many single-sided media types as desired. Alternatively, each winding of the single facer media type may be done separately, and the portions may be brought together and sealed as a secondary process.

FIG. 24B is a top schematic view of an exemplary filter media element 2450, showing a coiled configuration with two types of flutes forming the filter media. The filter media element has two types of flutes: a first medium 2460 and a second medium 2470. The media is shown in a rolled configuration with the two types of flutes separated from each other. In this exemplary embodiment, the ratio of the packet entry areas 2470 to 2460 is about 2: 1.

Fig. 25A is a top schematic view of an exemplary filter media element 2500, showing a coiled configuration with three types of filter media: first medium 2510, second medium 2520, and third medium 2530. The media is shown in a rolled configuration, wherein the media are separated from each other by: filter medium 2520 is laid down first, and then second medium 2520 is laid down on top of medium 2510, and third medium 2530 is laid down on top of medium 2520. In this exemplary embodiment, the ratio of the packet entry areas 2510 and 2520 and 2530 is about 4:3: 3.

FIG. 25B is a top schematic view of an exemplary filter media element 2550, showing a coiled configuration with three types of filter media. Filter media element 2550 has first media 2560, second media 2570, and third media 2580. The media is shown in a rolled configuration, with three types of media separated from each other. In this exemplary embodiment, the ratio of packet entrance areas 2560 to 2570 to 2580 is about 4:3: 3.

Fig. 26A is a top schematic view of an exemplary filter media element 2600 illustrating a coiled configuration with two types of filter media. Filter media element 2600 has two types of filter media: first media 2610 and second media 2620. The media is shown in a rolled configuration, where the two types of media are separated from each other by laying filter media 2620 first and then laying filter media 2620 on top of media 2610. In this exemplary embodiment, the ratio of the packet entry areas 2610 and 2620 is about 1: 1.

Fig. 26B is a top schematic view of an exemplary filter media element 2650, showing a coiled configuration with two types of filter media. The filter media element has two types of filter media: a first medium 2660 and a second medium 2670. The media is shown in a rolled configuration, with the two types of media separated from each other. In this exemplary embodiment, the ratio of packet entry areas 2660 and 2670 is about 1: 1.

Aspects may be better understood with reference to the following examples, in which element a, element B, and element C are compared to one another. Element a consists entirely of medium a with grooves having a width of about 10.7 mm and a height of 3.2 mm and a tapered cross-sectional area. Element B consists entirely of medium B with grooves having a width of about 8.0 mm and a height of about 2.7 mm and a tapered area. The cell density per square centimeter of cell a was about 2.8 and cell B was about 4.4. Element C consists of 50% by volume of medium a and 50% by volume of medium B to form a mixed medium. FIG. 27 shows a medium A used in a mediumLoading curves for filter elements made from B and mixed media. The load curve shows the pressure drop of the filter element as the gram of dust increases from zero to less than 500 grams. As shown in FIG. 27, media B and the mixing media start at very similar restriction levels (approximately 2.5 inches H)₂0) And media A has about 3.2 inches H₂0, higher initial pressure drop. As the dust begins to load, the pressure drop across all elements increases, however the pressure drop for media a and mixed media increases more slowly than for media B, where the pressure drops for media a and media B cross (or are the same) at about 125 grams of dust. Thus, the mixed media closely tracks media B just as the dust load begins, and then closely tracks media a as the dust load increases to higher levels. In other words, the mixed media has an initial pressure drop similar to media B, but a load similar to media a.

To further test the improved filtration performance, a test station was provided having a dual duct system of 5 to 9 cubic meters of air flow per minute configured to measure pressure drop and outlet restriction values. The relative performance of media elements formed using combinations of filter media was investigated by constructing various filter element designs. These elements are formed from z-flow media arranged in a stacked configuration. Each of these elements had an inlet face of 150 by 150 mm and an outlet face of 150 by 150 mm and a depth of 150 mm. The filter element is made of two types of media: medium a and medium B. The Media slot configurations for Media a and Media B are consistent with those shown in U.S. patent No. 9,623,362 entitled Filter Media Pack, Filter element, and Air Filtration Media to inventor Scott M brown (Scott m.brown) and assigned to donansen Company, Inc. Media a and B are predominantly cellulosic media. Media a had a slot height of about 0.092 inches, a slot width of about 0.314 inches, and a slot length (including slot plugs) of about 150 millimeters. Media B has a slot height of about 0.140 inches, a slot width of about 0.430 inches, and a slot length (including slot plugs) of about 150 millimeters. The first type of "segmented" media element is an assembled package of media a and media B positioned adjacent to each other in parallel flow. A second type of "layered" media element includes alternating sheets of media a and media B.

Fig. 28A-30B show performance results for various media configurations, including dust loading and pressure drop. Fig. 28A, 29A, and 30A show the results of the segmentation configuration (media a grouped together and all media B grouped together); and fig. 28B, 29B and 30B show the results of a layered structure (in which at least some of the medium a and the medium layer are mixed). Thus, the media construction includes either media a, media B, or media a and media B in various volume percentages. The media represented as 0% at the far left of each graph is without media a and is therefore entirely media B. The rightmost medium, denoted 100%, is medium a only and thus no medium B. The Y-axis contains the ISO fine dust loading measured in grams, and the pressure drop measured in inches of water.

Fig. 28A and 28B show performance results for various media configurations, including dust loading and pressure drop, at a cubic flow rate of 5.83 cubic meters per minute. From fig. 28A and 28B it can be observed that the best performance, in particular the highest dust load, is achieved with the mixed media: the mixed media element containing both media a and media B has a higher dust loading capacity than either media a or media B alone.

Fig. 29A and 29B show performance results for various media constructions at a cubic flow rate of 7.37 cubic meters per minute, including dust loading and pressure drop. Also, as in fig. 29A and 29B, the best performance is achieved with a mixed medium of medium a and medium B.

Fig. 30A and 30B show performance results for various media configurations, including dust loading and pressure drop, at a cubic flow rate of 8.78 cubic meters per minute. It can be observed from fig. 30A and 30B that the best performance, in particular the highest dust load, is achieved again with the mixed media.

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. Thus, for example, reference to a composition containing "a compound" includes mixtures of two or more compounds. It should also be noted that the term "or" is generally employed in its sense including "and/or" unless the content clearly dictates otherwise.

It should also be noted that, as used in this specification and the appended claims, the phrase "configured to" describes a system, device, or other structure that is constructed or arranged to perform a particular task or take a particular configuration. The phrase "configured to" may be used interchangeably with other similar phrases as arranged and configured to, constructed and arranged to, constructed to, manufactured to, arranged to, etc.

Aspects have been described with reference to various specific and preferred embodiments and techniques. It should be understood, however, that many variations and modifications may be made within the spirit and scope herein.

The embodiments described herein are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices.

All publications and patents mentioned herein are incorporated herein by reference. The publications and patents disclosed herein are provided solely for their disclosure. Nothing herein is to be construed as an admission that the inventors are not entitled to antedate any publication and/or patent, including any publication and/or patent cited herein.