echnical Field The present invention relates to fluid filtering devices, more particularly devices using generally ^* corrugated filter media in combination with flat media.

Background of the Invention In creating a fluid filter, an attempt is made to maximize the loading capacity while simultaneously minimizing the volume of the filter itself ^* and its face velocity. Simultaneously, it is desirable _. to simplify or eliminate the housing structure necessary to support the filter. -All of these factors must be con¬ sidered with an eye to keeping the overall cost to a minimum.

Pleated paper filters with rigid housings have long been the industry standard for most filtering application. These ^' filters, ^" however, require- relatively expensive housing structures and have relatively low filter densities and loading capacities.

Attempts have been made to increase the filter density and loading capacity of filter elements. One such filter is described in U. S. Patent No. _. 2,322,548 issued to Sig und wherein an impervious board matrix separates a flat filtering sheet which is rolled into a cylindrical shape. Filtering occurs when the fluid entering the intake side must cross through the inner walls at a right angle to exit by the outlet side. U. S. Patent No. 2,210,397 issued to Dreiss uses a simi¬ lar to orthogonal flow filtering scheme ^' by carefully aligning two sheets of substantially flat filter paper with a specially designed top and bottom plates to direct airflow. U. S. Patent No. 3,020,977 issued to

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Huppke et al introduces the additional, feature of corru gated material between flat sheets, although the corru gated material performs no filtering function, merel acts as ^' a spacer. Likewise, U. S. Patent No. 2,397,75 issued to Sigmund employs a corrugated member as spacer. None of these devices is able to achieve th high filtering density desired because of the use materials whichr are merely structure rather than bot structural and performing a filtering function. The present invention recognizes the value orthogonal filtering flow while insuring that every el ment of the filter performs both a structural and filtering function, rather than merely one or the othe Thus, the desired result of maximizing strength a filter density while reducing face velocity and co are achieved by the present invention.

Brief Summary of"the Invention The - present inveϊϊt-ion is, in one embodimen directed to a fluid filter for removing particula matter including a roll of substantially flat filt media, a role of corrugated filter media, the nesting said rolls together to form a composite roll so th alternate corrugated and .flat media layers are contact, thereby forming a plurality of longitudin flutes extending through the roll from one end to t other, the flutes being formed in two spiral series o on either side of the corrugated media, sealant mea allowed to one of the spiral series of flutes at one e of the composite roll and applied to the other series flutes at the other end of composite roll so that flu entering the remaining open flutes on _. one end of t roll must exit via the other series of open flutes the other end and thereby being filtered.

According to a further aspect of the inventio a fluid filter is disclosed including a top, bottom, two

sides and a front and back, said top, bottom and tw sides being fluid impervious, a fluid filter dispose within said sides, the element including a first • corru gated layer of filter media having one surface in con tact with the top corrugations being orthogonal to th two sides of the filter, a second corrugated layer o filter media with one surface in contact with th bottom, the corrugations of . the second layer bein aligned in parallel ^' with the corrugations of the firs layer and intermediate element of filter media dispose between and in contact with the remaining sides ^' of th first and second layer ^' s, the first, second and inter mediate layers forming together a plurality of tubula passages having ends opened at the front and back sealant means for preventing the entry and exit o fluids therethrough applied to every other of the ope nings of said first and second layers on the front sid and applied to the openings on the back side on ^' th remaining openings which ar ^* e.. opened to the front side, so that the fluids entering the unsealed openings in on side of the filter must exit the filter on the othe side of a different passage.

According to a further aspect of the invention there is disclosed a fluid filter having four sides, an top and bottom comprising a pair of fluid ^' imperviou planar members in a spaced relationship, a filter ele ment bounded on its upper and lower sides by the plana members, the element including a filter pack having first corrugated filter media having longitudinal peak and valleys thereacross, a second layer atop the firs layer, the second layer being of substantially fla filter media, a third layer atop the second layer, th third layer being of corrugated media having longitudi nal peaks and valleys which are oriented orthogonal t the corrugations of the first layer, sealant means

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applied to the first and second layers on peripheral edges thereof which are parallel to the axis defined by the longitudinal corrugations of the third layer for preventing entry and exit of fluid therethrough, said sealant means also being applied to the second and third layers on the peripheral edges which are paralle to the axis defined by the longitudinal corrugations o the first layer, -v..

According ^" to ^' another aspect of the invention, the filter in the above paragraph may include additiona sealant means for blocking passage of fluid therethrough applied to the two adjacent sides of th filter so that only the two remaining unsealed side will allow passage of fluids into and out of the filter. Brief Description of the Drawings

The specific embodiments of the invention hav been chosen for the purpose of illustration and descrip tion . and are shown in the^-accompanying drawings whic form a part of the specification wherein: FIGURE 1 is a perspective view of a cylindrica filter embodiment of the present invention;

FIGURE 2 is a cross sectional view taken alon lines 2-2 of FIGURE 1;

FIGURE 3 ^' is a perspective of the embodiment i FIGURE 1 partially unassembled _?

FIGURE 4 is an enlarged fragmentary portion o the embodiment in FIGURE 1;

FIGURE 5 is a perspective view of a secon embodiment of the invention; FIGURE 6 is a cross sectional view taken alon line 6-6 of FIGURE 5;

FIGURE 7 is a perspective view of a right angl embodiment of the present invention;

FIGURE 8 is an exploded perspective view of th embodiment shown in FIGURE 7;

^' FIGURE 9 is a plan view of an embodiment show in FIGURE 10;

FIGURE 10 is a perspective view of a cross flow embodiment of the present invention;

FIGURE 11 . is an enlarged fragmentary .perspec tive of the embodiment shown in FIGURE 10; and FIGURE 12 is an exploded perspective view o the embodiment in FIGURE 10.

Detailed Description of the Invention The. preferred embodiments of the present inven tion are directed" to a commercially feasible, high den sity fluid filter which maintains high structura integrity without the need for additional. housin elements.

Reference should be had to FIGURES 1-4 wher there is shown a first embodiment of the presen invention. In FIGURES 1 and 2, a cylindrical filterin element 12 is shown in a typical installation wherei the bottom of filter 12 rests upon support 14 which is attached to the fluid intake 16 ^{^} of the device needing filtered fluid. A bolt 18 uns the length of element 1 20 through a center hole 20 therein and by means of washer 22 and a wing nut ^' 24 the filter is affixed to the base 14. Alternatively, center hole 20 may be seale and the filter may be affixed to the base by clamps.

Washer 22 should be of a sealing type pre ferably made of a rubber or plastic material in order t prevent any incoming fluid from bypassing filter throug hole 20 which runs the length of the filter element.

Base 14 includes a cup shaped reduction portion 15 and a flat section 17 to engage to bottom edge of the filter which preferably includes a seal 19 for fluid tight engagement of the filter and base. Extending vertically from flat section 17 is a cylindrical portion 21 which may perferably be used as a guide for proper insertion of the filter and to protect it from rocks and other debris.

It is noted that fluid intake in this device is shown by arrows 26 occurs at the top end thereof and that filter fluids exit by the bottom end as shown by

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^• arrows 28. Filtering occurs within the body of filt as shown by arrows 30, details of which will explained when reference is made to FIGURE 6 of further embodiment. The filter element 12 preferably includes impervious barrier element 32 (shown in FIGURE 2) whi is cylindrical in shape so as to be sized to receive t body of element 12 therewithin. The purpose of barri 32 is primarily to prevent entry of uncleaned fluid v the sidewalls <_ ^* £ the element, thereby directing ^' it the flow shown by arrows 26. The barrier is not need for structural integrity and therefore may be. made of coating of sealant material such as urethane or silic rubber or hot melt caulk rather than a discrete fiber metal.

FIGURE 3 shows the construction of the filt in a partially unrolled state. In this embodiment, t layers of filter media are placed one on top of t other and rolled together. ^" The first layer 34 substantially flat filter media. The second layer 36 preferably made of a similar filter media; however, is preferably corrugated such that it has a plurality side by side peaks and valleys, preferably formed into sinusoidal configuration. Media layer 36 may also corrugated to have a different configuration, such triangular or trapezoidal shape or the like, howeve the sinusoidal shape appears to maximize the filteri surface available and thus the loading capacity thereby increased. The two layers of filter media and 36 are nexted together such that when they a rolled into a cylindrical shape to create a composi roll, it appears that the filter is made up of alterna layers of media which spiral inwardly toward center. It is preferable to have layer 34 as outermost layer of the composite roll; however, it not essential for the operation of the invention.

In the preferred construction, a bead sealant such as glue 38 is laid between layer 34 and one

face 36a of layer 36. When the two layers are brought together, a series of hollow flutes or passages 40 are formed bounded by layer 34 and face 36a. The flutes may be tubular in shape with varied cross sections. The glue 38. ^' acts as a sealant on the peripheral edge where it is preferably placed and causes the passage 40 to be sealed against entry or exit of fluid at this end.

A second bead of glue or sealant material 42 is placed between fa_ce 36b of layer 36 and layer 34 -toward the peripheral edge of the remaining end of the filter. When the layer 34 and face 36b are brought together, a second set of tubular passage 44 are formed. Their ends are sealed by bead 42 such that fluid may not enter or exit passages 44 at this end. The filter 'is. completed by rolling the layers together and allowing the sealant bead to solidify. Bead 42 in FIGURE 3 is shown as it would appear before the layers are brought together-, and do not show the spreading and filling which -iil occur at that time. In the filtering process, fluid entering the filter at one end may only enter the open passage

(either 40 or 44, depending on the end) and must exit flutes which are open on the other end of the filter. ^'

During this process, filtering occurs when the fluid must travel in a direction substantially orthogonal to that of its intake direction, pass through a sidewall of either .corrugated media 36 or flat media 34 on its way to a passage with an open end. It is noted that all elements of the filter media perform a filtering function, and are not merely used for structural purposes.

If it is desired to insure a solid bond between the peaks and valleys of layer 36 and layer 34, the com¬ posite roll may be made under heat and pressure so that the layers will adhere to each other at points of con¬ tact or alternatively, adhesive may be added to the peaks to insure a good bond. It is, however, not a problem that there be such a bond for filtering purposes

because fluid which might leak through between th layers must still pass through a layer in order to exi the filter, the bond assist only with respect to struc tural aspects of the filter. As an alternative to applying beads 38 and 42, it is possible to roll the two . sheets of media into th composite roll and inject sealing material, such as ho melt glue by glue gun, into the appropriate passage end as per above. An alternative embodiment is shown in. FIGURES and 6. This embodiment operates in substantially th same manner as the first embodiment. However, it i formed into a rectangular shape for convenience. I FIGURE 5 there is shown a filter element 112 having top 114, a bottom, (not visible) two sides 116 and 11 and a front 120 and back 122. Sides 116, 118 and th top and bottom are made of a barrier of fluid imperviou material which may either be^-a planar members of a soli structural material such as fiberboard, plastic or meta or may alternatively be a coating of a fluid sealan material, which may be applied in a liquid form and le harden. In this embodiment, layers of corrugated filte media 124 are alternated with substantially flat medi 126 creating a sandwich-like arrangement. The minimu requirements for such a filter are the fluid imperviou walls as shown and at least one layer of corrugate filter media plus the end sealant as explained below The sandwich of alternate layers creates two series o tubular flutes or passages, 130 and 132, one series o either side of every corrugated filter media 124 Sealant means such as hot melt glue or- the like i applied to passages 132 on the front end 120 for ever layer of filter media. The sealant means may be applie by injection or as previously in the first embodiment b laying a bead of sealant on the filter media toward

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front edge 120. Passages 130 which are not blocked a front 120, are sealed in a similar manner on backsid 122. FIGURE 6 shows in cross section of sealant 13 which is applied to passages 132 and sealant 131 applie to passage 130 opposite faces of the filter.

One possible flow pattern is shown by arrow 136 wherein fluid enters passages 130, crosses throug the corrugated media layer 124 and exits by passages 13 on the other end. Alternatively, fluid may pas upwardly or downwardly across the flat media layer 12 and exit via an adjacent passage above or below th passage of entry.

As fluids pass through a media wall, filterin occurs and particulate' matter becomes lodged within the media itself. Because this loading will increase the face velocity at that point, particulate matter will tend to be collected at other-, points along the walls thereby evenly distributing the particulate matter throughout the filter until it is fully loaded. - A further embodiment of the present invention is shown in FIGURES 7 and 8 of the drawings. This embo¬ diment provides for right angle fluid flow as shown in FIGURE 7 wherein filter element 212 allows for intake of fluid ^' at face 214 as indicated by arrows 216 and there the outflow occurs at face .218 as . indicated by arrows 220. Filter element 212 preferably includes a fluid impervious top and bottom wall 222 and 224, respectively. Two adjacent sidewalls 226 and 228 are also provided. Disposed between the aforementioned four walls is the sequence of layers of filter media formed at a filter pack 230 which are shown most clearly in an exploded view in FIGURE 8. Walls 222-228 are preferably made larger than the filter pack 230 in order to form a partial, housing for the filter which helps direct flow.

The walls extend beyond the filter pack forming a par tial housing around faces 214 and 218. A divider wal 232 is preferably disposed between top and bottom wall 222 and. 224 and a corner edge 215 of filter pack 230 a preferably a 135 degree angle relative to a face of th filter pack with one edge of the divider in abutmen with edge 215 defined as intersection of adjacent face of filter ^' pack . _^ 230. This divider serves to clearl segregate inlet and outlet flows. Turning to FIGURE 8, the preferred sequence o filter elements can be seen. Filter pack 230 include at least one corrugated layer of filter media 234, flat layer of filter media 236 placed atop layer 234 an a third layer of corrugated filter media 238 set ato layer 236 where the corrugations of layer 238 and 23 are substantially orthogonal to each other. The orien tation may also _be less than 90., degrees and still pro duce the desired result _ _^ however, the fabricatio becomes more difficult. -T-he combination of- flat an corrugated sheets of media create hollow passages, o flutes. Sealant means is applied to the flutes as show in FIGURE 8 as follows. Opposite edge 240 and 242 alon layer 234 are coated with a fluid impervious barrie material which will prevent the entry or exit of fluid therethrough. On edge 244, the sealant material i applied to close passages on both faces of layer 234 Application of sealant may also be made in the sam manner as explained for previous embodiments herein.

On layer 238, edges 246 and 248 are sealed i the same manner as edges 240 and 242. Likewise, th passages on both sides of sheet 238 along edge 250 ar sealed in the same manner as that of edge 244. Thi sealing sequence is repeated for however many layers ar desired such as that shown in FIGURE 8. Flat layer 23 may or may not be sealed when the appropriate edges of

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the corrugated layers 234 and 238 are sealed. It is likely that layer 236 will be sealed at its peripheral edge along with its adjacent corrugated layers for purely ^" practical reasons of size, however, since fluid will not as a practical matter pass through the filter via this edge, there is no necessity for sealant.

The flow produced is shown by arrows 252 wherein fluid e-nters passage 254, for example, is blocked by the sealant on end 250 thereof and must exit by passing through, a layer 234 which resides between two layers of corrugated filter media. The fluid may then exit by a passage 256 which is oriented orthogonally to that of passage 254. Thus, the intake and outlet flows are at right angles without the need for additional housing apparatus to achieve this flow redirection.

FIGURES 9, 10 and 11 disclose a cross flow embodiment of this invention. FIGURE 9 shows in schema

^• tic 'form by means of arrows^--310 the fluid flow within filter element 312. In this embodiment, fluid .may enter by two opposing side walls and exits orthogonally in either direction as filter fluid through the remaining sidewalls.

FIGURE 10 shows the location of the layers of filter media relative to the top and bottom fluid barriers 314 and 316, respectively. It is preferable to make the top and bottom barriers larger than the filter pack so as to provide means for directing the airflow within the filter. Four divider walls 318 are inter¬ posed between top and bottom barriers 314 and 316 at a 135 degree angle and in abutment with each corner of the filter pack in a manner similar to that of wall 232 in FIGURE 7, except that here the divider walls are employed on all four edges of the pack as shown in the figure. These walls eliminate the need for a separate housing for separating fluid intake and outlet.

The arrangement of layers of filter media in this embodiment is similar to that as shown in the pre¬ vious embodiment in FIGURES 7 and 8, except for the points which will be explained below. FIGURE 11 shows an enlarged fragmentary perspective of this filter pack 320 and in exploded perspective in FIGURE 12. The filter pack 320 pre¬ ferably rectangular with four ^' sides 311, 313, 315 and 317, none of whiόh are entirely sealed off from entry o exit of fluids.

As in the previous embodiment, there is a firs layer of corrugated filter media 322, a second layer o substantially flat media 324 and a third layer of corru gated media 326 with _. .its corrugations aligned orthogo nally to that of layer 322.

Edges and passages of the filter pack ar sealed as follows. On sidewall 311, corrugated medi layer 322 ■ has its flutes or tubular passages lef unsealed. Layer 32 ^' 6 (and optionally 324) are coated o injected with sealant material 340 on edge 311 ^" so as t prevent entry or exit through these exposed sides of th passages. See FIGURE 11 for detail. The sequence o sealing on edge 311 is repeated for however many layer there are. On side 315 opposite 311 precisely the sam pattern of sealant is applied so that passages formed b the layers- 322 and 324 will be open to both sides 31 and 315. ^*

On side 317, layer 322 is sealed along its edg as shown so that fluid may not enter or exit throug this portion of the layer and optionally along th adjoining flat layer 324. Corrugated media- layer 326 i unsealed on this end with respect to the passages whic are formed by layers 326 and 324.

On side 313, precisely the same arrangement for sealing is employed as was used on side 317 so that

^• flutes on either side of layer 326 are open on both ends. This sequence of sealing is repeated for however many layers of filter media are in this pack.

When a filter pack 320 is assembled it will appear as shown in FIGURE 11 in the enlarged fragmentary view.

One possible flow pattern for this filter is shown in FIGURE 10 wherein arrows 350 indicate the entry of fluids from two sides while arrows 352 illustrate the exit of the fluids from the remaining two sides or ^' thogo- nal to arrow 350. Although this flow pattern is suggested, it is understood that alternative flow pat¬ terns are possible depending on the application of the filter. Numerous characteristics and advantages of the invention have been set forth in the foregoing descrip tion together with' the details of the structure and function of the invention. Novel features thereof are pointed out in the appended claims. The disclosure, however, is illustrative only, and changes may be made in detail especially in atte-rs of size, shape, arrange¬ ment of parts, within the principle of the invention to the full extent intended by the broad general meaning of • the terms in which the appended claims are expressed.