Filter element with a spacer

Abstract

A filter element for filtering a fluid that comprises a pleated filter media and a support structure. The pleated filter media comprises pleats that define an upstream gap along an upstream surface of the pleated filter media and a downstream gap along a downstream surface of the pleated filter media. The support structure extends along the downstream surface of the pleated filter media and supports the pleats. The support structure is folded into two layers comprising a first layer and a second layer within the downstream gap. The first layer inner surface and the second layer inner surface are positioned adjacent to each other within the downstream gap. The support structure comprises at least one spacer that increases a distance between the first layer outer surface and the second layer outer surface such that the differential pressure drop through portion of the support structure that is within the downstream gap is decreased.

What is claimed is: 
     
         1 . A filter element for filtering a fluid, the filter element comprising:
 a pleated filter media comprising pleats that define an upstream gap along an upstream surface of the pleated filter media and a downstream gap along a downstream surface of the pleated filter media; and   a support structure extending along the downstream surface of the pleated filter media and supporting the pleats, the support structure folded into a first layer and a second layer within the downstream gap of the pleated filter media, the first layer comprising a first layer outer surface and a first layer inner surface, the second layer comprising a second layer outer surface and a second layer inner surface, the first layer inner surface and the second layer inner surface positioned adjacent to each other within the downstream gap, the support structure comprising at least one spacer that separates the first layer outer surface and the second layer outer surface.   
     
     
         2 . The filter element of  claim 1 , wherein the support structure comprises a mesh that comprises radial-parallel wires and radial-normal wires. 
     
     
         3 . The filter element of  claim 2 , wherein the radial-parallel wires and the radial-normal wires mesh are substantially perpendicular to each other to form a plain square weave mesh. 
     
     
         4 . The filter element of  claim 2 , wherein the radial-parallel wires and the radial-normal wires have different diameters. 
     
     
         5 . The filter element of  claim 4 , wherein the radial-parallel wires have a larger wire diameter than the radial-normal wires. 
     
     
         6 . The filter element of  claim 2 , wherein the radial-parallel wires are aligned with each other within the downstream gap. 
     
     
         7 . The filter element of  claim 2 , wherein a thickness of one layer of the support structure is equal to the diameter of the radial-parallel wires plus the diameter of the radial-normal wires. 
     
     
         8 . The filter element of  claim 2 , wherein a ratio of the diameter of the radial-parallel wires to the diameter of the radial-normal wires is from 2.0 to 4.0. 
     
     
         9 . The filter element of  claim 1 , wherein the thickness of the downstream gap is approximately equal to twice the thickness of one layer of the support structure. 
     
     
         10 . The filter element of  claim 1 , wherein the first layer outer surface is an upstream surface relative to the first layer inner surface and the first layer inner surface is a downstream surface relative to the first layer outer surface, and wherein the second layer outer surface is an upstream surface relative to the second layer inner surface and the second layer inner surface is a downstream surface relative to the second layer outer surface. 
     
     
         11 . A filter cartridge configured for attachment to a filter head in a filtration system, the filter cartridge, comprising:
 a filter housing; and   a filter element positioned within the filter housing, the filter element comprising:
 a first endplate; 
 a second endplate; 
 a pleated filter media extending between the first endplate and the second endplate, the pleated filter media comprising pleats that define an upstream gap along an upstream surface of the pleated filter media and a downstream gap along a downstream surface of the pleated filter media; and 
 a support structure extending along the downstream surface of the pleated filter media and supporting the pleats, the support structure folded into a first layer and a second layer within the downstream gap of the pleated filter media, the first layer comprising a first layer outer surface and a first layer inner surface, the second layer comprising a second layer outer surface and a second layer inner surface, the first layer inner surface and the second layer inner surface positioned adjacent to each other within the downstream gap, the support structure comprising at least one spacer that separates the first layer outer surface and the second layer outer surface. 
   
     
     
         12 . The filter cartridge of  claim 11 , wherein the support structure comprises a mesh that comprises radial-parallel wires and radial-normal wires. 
     
     
         13 . The filter cartridge of  claim 12 , wherein the radial-parallel wires and the radial-normal wires mesh are substantially perpendicular to each other to form a plain square weave mesh. 
     
     
         14 . The filter cartridge of  claim 12 , wherein the radial-parallel wires and the radial-normal wires have different diameters. 
     
     
         15 . The filter cartridge of  claim 14 , wherein the radial-parallel wires have a larger wire diameter than the radial-normal wires. 
     
     
         16 . The filter cartridge of  claim 12 , wherein the radial-parallel wires are aligned with each other within the downstream gap. 
     
     
         17 . The filter cartridge of  claim 12 , wherein a thickness of one layer of the support structure is equal to the diameter of the radial-parallel wires plus the diameter of the radial-normal wires. 
     
     
         18 . The filter cartridge of  claim 12 , wherein a ratio of the diameter of the radial-parallel wires to the diameter of the radial-normal wires is from 2.0 to 4.0. 
     
     
         19 . The filter cartridge of  claim 1 , wherein the thickness of the downstream gap is approximately equal to twice the thickness of one layer of the support structure. 
     
     
         20 . The filter cartridge of  claim 1 , wherein the first layer outer surface is an upstream surface relative to the first layer inner surface and the first layer inner surface is a downstream surface relative to the first layer outer surface, and wherein the second layer outer surface is an upstream surface relative to the second layer inner surface and the second layer inner surface is a downstream surface relative to the second layer outer surface.