Z-media having flute closures, methods and apparatus

Abstract

A single facer media is provided according to the invention. The single facer media includes a fluted sheet attached to a facing sheet and having a first end and a second end so that when the single facer media is formed into a media pack, the first end or the second end forms a media pack first face, and the other of the first end or the second end forms a media pack second face. Adhesive is provided between the fluted sheet and the facing sheet at the first end or the second end, and wherein the fluted sheet and the facing sheet are pushed together and adhered together at the location of the adhesive to provide a seal between the fluted sheet and the facing sheet. At least 25% of the flutes of the fluted sheet comprise at least one ridge extending along at least 50% of the flute length between adjacent peaks. Filtration media packs, filter elements, and methods for forming a single facer media are provided.

1 . A single facer media comprising:
 (a) a fluted sheet attached to a facing sheet and having a first end and a second end so that when the single facer media is formed into a media pack, the first end or the second end forms a media pack first face, and the other of the first end or the second end forms a media pack second face;   (b) adhesive provided between the fluted sheet and the facing sheet at the first end or the second end, and wherein the fluted sheet and the facing sheet are pushed together and adhered together along the adhesive to provide a seal between the fluted sheet and the facing sheet; and   (c) wherein at least 25% of the flutes of the fluted sheet comprise at least one ridge extending along at least 50% of the flute length between adjacent peaks.   
   
   
       2 . A single facer media according to  claim 1 , wherein at least 25% of the flutes in the fluted sheet comprise at least two ridges extending along at least 50% of the flute length between adjacent same side peaks. 
   
   
       3 . A single facer media according to  claim 1 , wherein the fluted sheet exhibits a flute width height ratio greater than 2.5. 
   
   
       4 . A single facer media according to  claim 1 , wherein the fluted sheet exhibits a flute width height ratio greater than 3.0. 
   
   
       5 . A filtration media pack comprising the single facer media according to  claim 1 , and constructed with an adhesive bead to form the media pack having inlet flutes for receiving dirty fluid and outlet flutes for discharging filtered fluid, and wherein the dirty fluid passes through the fluted sheet or the facing sheet to provide filtering thereof. 
   
   
       6 . A filtration media pack according to  claim 5  provided in a coiled arrangement. 
   
   
       7 . A filtration media pack according to  claim 5  provided in a stacked arrangement. 
   
   
       8 . A filtration media pack according to  claim 5 , wherein the media pack has a flute density greater than 35 flute/inch 2 . 
   
   
       9 . A filtration media pack according to  claim 5 , wherein the media pack has a flute density greater than 45 flute/inch 2 . 
   
   
       10 . A filtration media pack according to  claim 5 , wherein the media pack has a flute volume asymmetry greater than 30%. 
   
   
       11 . A filtration media pack according to  claim 5 , wherein the media pack has a flute volume asymmetry greater than 70%. 
   
   
       12 . A filtration media pack according to  claim 5 , wherein the media pack comprises tapered flutes. 
   
   
       13 . A filtration media pack according to  claim 12 , wherein the tapered flutes comprise a first end having a first cross-sectional area and a second end having a second cross-sectional area, wherein the first cross-sectional area and the second cross-sectional area are different, and wherein the seal provided by pushing the fluted sheet and the facing sheet together is at one of the first end or the second end. 
   
   
       14 . A filter element comprising a media pack and a seal around the media pack for engaging a housing, the media pack comprising a single facer media and an adhesive bead to form inlet flutes for receiving dirty fluid and outlet flutes for discharging dirty fluid, the single facer media comprising:
 (a) a fluted sheet attached to a facing sheet and having a first end and a second end so that when the single facer media is formed into a media pack, the first end or the second end forms a media pack first face, and the other of the first end or the second end forms a media pack second face;   (b) adhesive provided between the fluted sheet and the facing sheet at the first end or the second end, and wherein the fluted sheet and the facing sheet are pushed together and adhered together along the adhesive to provide a seal between the fluted sheet and the facing sheet; and   (c) wherein at least 25% of the flutes of the fluted sheet comprise at least one ridge extending along at least 50% of the flute length between adjacent peaks.   
   
   
       15 . A filter element according to  claim 14 , further comprising a handle extending axially from the media pack. 
   
   
       16 . A filter element according to  claim 14 , wherein the media pack has a flute density greater than 35 flute/inch 2 . 
   
   
       17 . A filter element according to  claim 14 , wherein the media pack has a flute density greater than 50 flute/inch 2 . 
   
   
       18 . A filter element according to  claim 14 , wherein the media pack has a flute volume asymmetry greater than 30%. 
   
   
       19 . A filter element according to  claim 14 , wherein the media pack has a flute volume asymmetry greater than 70%. 
   
   
       20 . A filter element according to  claim 14 , wherein the media pack comprises tapered flutes. 
   
   
       21 . A filter element according to  claim 14 , wherein the media pack comprises non-tapered flutes. 
   
   
       22 . A filter element according to  claim 14 , wherein the seal around the media pack for engaging a housing comprises a radial seal. 
   
   
       23 . A filter element according to  claim 14 , wherein the seal around the media pack for engaging a housing comprises an axial pinch seal. 
   
   
       24 . A method for forming a single facer media comprising:
 (a) adhering a fluted sheet to a facing sheet by application of adhesive between the fluted sheet and the facing sheet; and   (b) pushing the fluted sheet toward the facing sheet at the location of the adhesive to form an adhesive seal; wherein at least 25% of the flutes of the fluted sheet comprise at least one ridge extending along 50% of the flute length between adjacent peaks.   
   
   
       25 . A method according to  claim 24 , wherein the step of pushing the fluted sheet toward the facing sheet at the location of the adhesive to form an adhesive seal comprises applying a series of rolls to the fluted sheet and facing sheet, the series of rolls comprising:
 (a) a creaser wheel constructed to push the fluted sheet toward the facing sheet;   (b) a crowning wheel having a surface for engaging the fluted sheet and further pushing the fluted sheet toward the facing sheet; and   (c) a flattening wheel having a surface constructed for flattening the fluted sheet relative to the facing sheet to provide a relatively flat surface.   
   
   
       26 . A method according to  claim 24 , further comprising:
 (a) slitting the fluted sheet and facing sheet at the location of the adhesive seal to form a first single facer media and a second single facer media, wherein the first single facer media and the second single facer media both include a relatively flat edge that is closed to the flow of unfiltered fluid therethrough.   
   
   
       27 . A method according to  claim 26 , wherein the method provides a consistent flute closure without a step of indenting the flute prior to the step of pushing the fluted sheet toward the facing sheet at the location of the adhesive to form an adhesive seal. 
   
   
       28 . A method according to  claim 24 , wherein the adhesive is applied as a continuous adhesive strip. 
   
   
       29 . A method according to  claim 24 , wherein the adhesive is applied as a discontinuous adhesive strip.