초록 ▼

A corrugated web having tapered flutes is usable in straight-through flow filter elements. The corrugated web can be made by passage between a pair of corrugated rollers having tapered teeth. Methods of making usable corrugated rollers include methods for generating the tapered teeth at the end poin

A corrugated web having tapered flutes is usable in straight-through flow filter elements. The corrugated web can be made by passage between a pair of corrugated rollers having tapered teeth. Methods of making usable corrugated rollers include methods for generating the tapered teeth at the end points and the extension between the end points. Corrugated webs may be made from a variety of media, including certain media that stretches in the machine direction. Methods of forming the corrugated web into filter elements (e.g., air filter elements) includes forming filter media by securing a flat sheet to the corrugated web. The filter media may then be wound into a filter element, including application of sealant during the winding process to close selected flutes.

대표청구항 ▼

What is claimed is: 1. A corrugated sheet for use in filter media; the corrugated sheet comprising: (a) a first web of media comprising a blend of synthetic and cellulose fibers; said blend comprising no greater than 80% synthetic fibers, by fiber weight, and a remaining amount being cellulose fibe

What is claimed is: 1. A corrugated sheet for use in filter media; the corrugated sheet comprising: (a) a first web of media comprising a blend of synthetic and cellulose fibers; said blend comprising no greater than 80% synthetic fibers, by fiber weight, and a remaining amount being cellulose fibers; said first web includes a resin content of at least 15%; (b) said first web having opposite first and second edges; said first web comprising a corrugated shape of alternating peaks and troughs; each of the peaks having a first peak end, a second peak end, and a peak extension between the first peak end and the second peak end; each of the troughs having a first trough end, a second trough end, and a trough extension between the first trough end and the second trough end; the alternating peaks and troughs forming a plurality of spaced flutes; (i) the trough of each flute decreasing in width, between adjacent peaks, from the first trough end to the second trough end; (ii) the peak of each flute increasing in width, between adjacent troughs, from the first peak end to the second peak end; wherein the first web comprises the blend of synthetic and cellulose fibers such that the media is both stretchable and retains the corrugated shape. 2. A corrugated sheet according to claim 1 wherein: (a) the first trough end of each flute has a first trough width, and the second trough end has a second trough width; (i) a ratio of the first trough width to the second trough width being at least 2:1; and (b) the first peak end has a first peak width, and the second peak end has a second peak width; (i) a ratio of the second peak width to the first peak width being at least 2:1. 3. A corrugated sheet according to claim 1 wherein: (a) the first trough end of each flute has a first trough width, and the second trough end has a second trough width; (i) a ratio of the first trough width to the second trough width being within a range of 3:1-7:1, inclusive; and (b) the first peak end has a first peak width, and the second peak end has a second peak width; (i) a ratio of the second peak width to the first peak width being within a range of 3:1-7:1, inclusive. 4. A corrugated sheet according to claim 3 wherein: (a) each flute has an angle of taper within a range of 0.25��-2�� inclusive. 5. A corrugated sheet according to claim 1 wherein: (a) said first peak end defines a first cross-sectional area; (b) said second peak end defines a second cross-sectional area; (i) said first cross-sectional area being 25-50% of said second cross-sectional area. 6. A corrugated sheet according to claim 1 wherein: (a) each of said peaks has first and second sloped sidewalls and a crest therebetween; (i) said first peak end having a radius of at least 0.2 inch at said crest; said first and second sloped sidewalls defining an angle of 8-12�� therebetween at said first peak end; (ii) said second peak end having a radius of at least 0.25 inch at said crest; and (b) each of said first peak end, second peak end, and peak extension has a uniform peak height of 0.1-0.25 inch. 7. A corrugated filter sheet according to claim 6 wherein: (a) each of said first trough end, second trough end, and trough extension has a uniform depth equal to said peak height. 8. A corrugated sheet according to claim 1 wherein: (a) said first web of media comprises 35%-75% synthetic fibers, by fiber weight, and a remaining amount being cellulose fibers. 9. A corrugated sheet according to claim 1 wherein: (a) said first web of media comprises 45-60% synthetic fibers, by fiber weight, and a remaining amount being cellulose fibers. 10. A corrugated sheet according to claim 1 wherein: (a) said first web includes: (i) a permeability of at least 15 cfm; and (ii) an average elongation in a machine direction of 4-7.5%. 11. A corrugated filter media structure comprising: (a) a corrugated sheet including: (i) a first web of media comprising a blend of synthetic and cellulose fibers; said blend comprising no greater than 80% synthetic fibers, by fiber weight, and a remaining amount being cellulose fibers; said first web includes a resin content of at least 15%; (ii) said first web having opposite first and second edges; said first web comprising a corrugated shape of alternating peaks and troughs; each of the peaks having a first peak end, a second peak end, and a peak extension between the first peak end and the second peak end; each of the troughs having a first trough end, a second trough end, and a trough extension between the first trough end and the second trough end; the alternating peaks and troughs forming a plurality of spaced flutes; (A) the trough of each flute decreasing in width, between adjacent peaks, from the first trough end to the second trough end; (B) the peak of each flute increasing in width, between adjacent troughs, from the first peak end to the second peak end; and wherein the first web comprises the blend of synthetic and cellulose fibers such that the media is both stretchable and retains the corrugated shape; (b) a second web of non-corrugated filter media oriented adjacent to said first web; (i) said second web of non-corrugated filter media being secured to said first web. 12. A corrugated filter media structure according to claim 11 wherein: (a) alternating flutes are closed to passage of fluid therethrough at a location adjacent said first edge. 13. A corrugated filter media structure according to claim 11 wherein: (a) said second web of non-corrugated filter media is secured to said first web of filter media by a sealant; (i) the sealant closing an area between said second web of non-corrugated filter media and said first peak ends. 14. A corrugated filter media structure according to claim 13 wherein: (a) said second web of non-corrugated filter media secured to said first web of filter media is in a coiled configuration. 15. A corrugated filter media structure according to claim 12 wherein: (a) said alternating flutes which are closed to passage of fluid therethrough at said location adjacent said first edge are open to passage of fluid therethrough at a location adjacent said second edge; and (b) remaining ones of said flutes are closed to passage of fluid therethrough at a location adjacent to said second edge and open to passage of fluid therethrough at a location adjacent said first edge. 16. A corrugated filter media structure according to claim 15 wherein: (a) sealant closes an area between said second web of non-corrugated media and said second trough ends along said second edge. 17. A corrugated sheet for use in filter media; the corrugated sheet comprising: (a) a first web of media comprising an average elongation in a machine direction of at least 3.5%; the first web comprising a blend of synthetic and cellulose fibers; said first web includes a resin content of at least 15%; (b) said first web having opposite first and second edges; said first web comprising a corrugated shape of alternating peaks and troughs; each of the peaks having a first peak end, a second peak end, and a peak extension between the first peak end and the second peak end; each of the troughs having a first trough end, a second trough end, and a trough extension between the first trough end and the second trough end; the alternating peaks and troughs forming a plurality of spaced flutes; (i) the trough of each flute decreasing in width, between adjacent peaks, from the first trough end to the second trough end; (ii) the peak of each flute increasing in width, between adjacent troughs, from the first peak end to the second peak end; wherein the first web comprises the blend of synthetic and cellulose fibers such that the media is both stretchable and retains the corrugated shape. 18. A corrugated sheet according to claim 17 wherein: (a) each of said peaks has first and second sloped sidewalls and a crest therebetween; (i) said first peak end having a radius of at least 0.2 inch at said crest; said first and second sloped sidewalls defining an angle of 8-12�� therebetween at said first peak end; (ii) said second peak end having a radius of at least 0.25 inch at said crest; and (b) each of said first peak end, second peak end, and peak extension has a uniform peak height of 0.1-0.25 inch. 19. A corrugated filter sheet according to claim 18 wherein: (a) each of said first trough end, second trough end, and trough extension has a uniform depth equal to said peak height. 20. A corrugated sheet according to claim 17 wherein: (a) said first web of media comprises 35%-75% synthetic fibers, by fiber weight, and a remaining amount being cellulose fibers. 21. A corrugated sheet according to claim 17 wherein: (a) said first web of media comprises 45-60% synthetic fibers, by fiber weight, and a remaining amount being cellulose fibers. 22. A corrugated sheet according to claim 17 wherein: (a) said first web of media comprises: (i) at least 30% synthetic fibers, by fiber weight, and a remaining amount being cellulose fibers; (ii) a permeability of at least 15 cfm; and (iii) an average elongation in a machine direction of 4-7.5%. 23. A corrugated filter media structure comprising: (a) a corrugated sheet including: (i) a first web of media comprising an average elongation in a machine direction of at least 3.5%; the first web comprising a blend of synthetic and cellulose fibers; said first web includes a resin content of at least 15%; (ii) said first web having opposite first and second edges; said first web comprising a corrugated shape of alternating peaks and troughs; each of the peaks having a first peak end, a second peak end, and a peak extension between the first peak end and the second peak end; each of the troughs having a first trough end, a second trough end, and a trough extension between the first trough end and the second trough end; the alternating peaks and troughs forming a plurality of spaced flutes; (A) the trough of each flute decreasing in width, between adjacent peaks, from the first trough end to the second trough end; (B) the peak of each flute increasing in width, between adjacent troughs, from the first peak end to the second peak end; and wherein the first web comprises the blend of synthetic and cellulose fibers such that the media is both stretchable and retains the corrugated shape; (b) a second web of non-corrugated filter media oriented adjacent to said first web; (i) said second web of non-corrugated filter media being secured to said first web. 24. A corrugated filter media structure according to claim 23 wherein: (a) alternating flutes are closed to passage of fluid therethrough at a location adjacent said first edge. 25. A corrugated filter media structure according to claim 23 wherein: (a) said second web of non-corrugated filter media is secured to said first web of filter media by a sealant; (i) the sealant closing an area between said second web of non-corrugated filter media and said first peak ends. 26. A corrugated filter media structure according to claim 25 wherein: (a) said second web of non-corrugated filter media secured to said first web of filter media is in a coiled configuration. 27. A corrugated filter media structure according to claim 24 wherein: (a) said alternating flutes which are closed to passage of fluid therethrough at said location adjacent said first edge are open to passage of fluid therethrough at a location adjacent said second edge; and (b) remaining ones of said flutes are closed to passage of fluid therethrough at a location adjacent to said second edge and open to passage of fluid therethrough at a location adjacent said first edge. 28. A corrugated filter media structure according to claim 27 wherein: (a) sealant closes an area between said second web of non-corrugated media and said second trough ends along said second edge.