Waved filter media and elements

Abstract

Various high performance, high efficiency filter media are provided that are cost effective and easy to manufacture. In particular, various filter media are provided having at least one layer with a waved configuration that results in an increased surface area, thereby enhancing various properties of the filter media. The filter media can be used to form a variety of filter elements for use in various applications.

1 . A filter media, comprising:
 a fine fiber filtration layer and a coarse support layer that holds the fine fiber filtration layer in a waved configuration and maintains separation of peaks and troughs of adjacent waves of the filtration layer, the coarse support layer having a density that is greater at the peaks than a density in the troughs.   
     
     
         2 . The filter media of  claim 1 , wherein the fine fiber filtration layer has a surface area that is at least about 50% greater than a surface area of the fine fiber filtration layer in a planar configuration. 
     
     
         3 . The filter media of  claim 1 , wherein the coarse support layer comprises a downstream coarse support layer, and the filter media further comprises an upstream coarse support layer, the fine fiber filtration layer being disposed between the upstream coarse support layer and the downstream coarse support layer. 
     
     
         4 . The filter media of  claim 3 , further comprising at least one additional filtration layer disposed between the downstream coarse support layer and the upstream coarse support layer. 
     
     
         5 . The filter media of  claim 4 , wherein the at least one additional filtration layer is formed from fibers having an average diameter greater than an average fiber diameter of fibers that form the fine fiber filtration layer. 
     
     
         6 . The filter media of  claim 3 , wherein the upstream coarse support layer, the fine fiber filtration layer, and the downstream coarse support layer all have a waved configuration. 
     
     
         7 . The filter media of  claim 3 , wherein the upstream coarse support layer is formed from fibers having an average diameter greater than an average diameter of fibers forming the fine fiber filtration layer and equal to or less than an average diameter of fibers forming the downstream coarse support layer. 
     
     
         8 . The filter media of  claim 3 , wherein the upstream and downstream coarse support layers comprise staple fiber layers, and the fine fiber filtration layer comprises at least one of a meltblown layer and a glass fiber layer. 
     
     
         9 . The filter media of  claim 6 , further comprising at least one of a planar layer disposed upstream of the upstream coarse support layer and a planar layer disposed downstream of the downstream coarse support layer. 
     
     
         10 . The filter media of  claim 9 , wherein the planar layer is formed from fibers having an average diameter less than an average diameter of fibers forming the upstream coarse support layer and the downstream coarse support layer, and greater than an average diameter of fibers forming the fine fiber filtration layer. 
     
     
         11 . The filter media of  claim 6 , further comprising a planar layer disposed downstream of the downstream coarse support layer, the planar layer being formed from fibers having an average diameter greater than an average diameter of fibers forming the upstream coarse support layer, the downstream coarse support layer, and the fine fiber filtration layer. 
     
     
         12 . The filter media of  claim 1 , wherein the fine fiber filtration layer comprises a meltblown layer. 
     
     
         13 . The filter media of  claim 1 , wherein the fine fiber filtration layer comprises a glass fiber layer. 
     
     
         14 . The filter media of  claim 1 , wherein the coarse support layer is formed from at least one binder fiber and at least one non-binder fiber. 
     
     
         15 . The filter media of  claim 1 , wherein the filter media has 2 to 6 waves per inch. 
     
     
         16 . The filter media of  claim 1 , wherein the filter media has a discharged DOP alpha value of greater than about 9. 
     
     
         17 . The filter media of  claim 1 , wherein the filter media has a discharged DOP alpha value of greater than about 11. 
     
     
         18 - 64 . (canceled) 
     
     
         65 . A pleated filter element, comprising:
 a filtration layer and a support layer mated together to form a waved filter media with a plurality of peaks and troughs, the waved filter media further comprising a plurality of pleats.   
     
     
         66 - 72 . (canceled) 
     
     
         73 . A bag filter, comprising:
 a housing; and   a plurality of filters mated to the housing, each filter having a pocket formed therein and configured to receive airflow therethrough, and each filter being formed from a filter media having a first fibrous layer that is held in a waved configuration by a second fibrous layer to form peaks and troughs.   
     
     
         74 - 81 . (canceled)