MXPA99011974A

MXPA99011974A - Method and device for separation of aerosol

Info

Publication number: MXPA99011974A
Application number: MXPA/A/1999/011974A
Authority: MX
Inventors: A Dushek Robert; S Gieseke Steven
Original assignee: Donaldson Company Inc
Priority date: 1997-06-27
Filing date: 1999-12-17
Publication date: 2000-09-04

Abstract

An arrangement for separating a hydrophobic liquid phase from a gaseous stream includes a coalescer filter, a housing, a gas flow direction arrangement, and a liquid collection arrangement. The coalescer filter includes a non-woven media of fibers. The housing includes an interior having a gas flow inlet and a gas flow outlet. The liquid collection arrangement is positioned within the housing construction and is oriented for receiving liquid collected from the coalescer filter and drained therefrom. Methods for conducting the separations are also provided.

Description

METHOD AND DEVICE FOR SEPARATING AEROSOLS FIELD OF INVENTION The present invention relates to systems and methods for separating hydrophobic fluids (such as oils) which are entrained as aerosols from gaseous streams (eg, air streams). Preferred devices also provide filtration of other fine contaminants, e.g., carbon material, from the gas streams. Methods for carrying out the separations are also provided.

BACKGROUND OF THE INVENTION Certain gas streams, such as fumes from diesel engines, carry substantial quantities of oils carried in them, as an aerosol. Most of the oil droplets within the aerosol are generally less than 0.1-5.0 micrometers in size. In addition, such gas streams also transport substantial amounts of fine contaminants, such as carbon contaminants. Such contaminants generally have an average particle size of about 0.5-3.0 micrometers. REF: 32343 In some systems, it is desirable to vent such gases to the atmosphere. In general, it is preferred that before the gases are vented to the atmosphere, they are cleaned in a substantial portion of the aerosol contaminants and / or organic particulates therein. In other cases, it is desirable to direct the air or gas stream into the equipment. When this is the case, it may be desirable to separate the aerosol and / or particulates from the stream during circulation, in order to provide benefits such as: reduced negative effects on the downstream equipment; improved efficiency, re-absorption of oils that would otherwise be lost; and / or to resolve environmental concerns. Many efforts have been directed to the previous types of concerns. The variables toward which improvements are desired are generally related to the following: (a) concerns regarding size / efficiency; that is, a desire for good separation efficiency and at the same time avoiding the requirement of a large separating system; (b) cost / efficiency; that is, a desire for good or high efficiency without requiring substantially expensive systems; (c) versatility; that is, the development of systems that can be adapted for a wide variety of applications and uses, without major reengineering; and (d) capacity. cleaning / regeneration; that is, development of systems which can be easily (or regenerated), if desired in this way, after prolonged use. U.S. Patent No. 4,627,406 discloses an oil separator element housed in a cover of an oil separator and includes alternately aligned perforated plates and plate type filter members. U.S. Patent No. 4,878,929 discloses a cartridge-type gas-liquid separator for separating air oil.

BRIEF DESCRIPTION OF THE INVENTION A device for separating a hydrophobic liquid phase from a gas stream comprises a coalescer filter, a housing construction, a gas flow direction device and a liquid collection device. The coalescer filter preferably comprises a medium of nonwoven fibers. The housing construction defines an interior and has a gas flow inlet and a gas flow outlet. The gas flow direction device is constructed and positioned to direct the flow of gas (eg Crankcase exhaust gas flow) through the coalescer filter as the gas is directed into and through the housing construction. The liquid collection device is placed within the housing construction and is oriented to receive the collected liquid within the coalescer filter and drained therefrom. Preferably, the coalescer filter comprises a removable panel construction, attachable to the device. Preferably, a liquid draining construction is in fluid communication with the liquid collection device. The liquid draining construction is constructed and positioned to selectively drain hydrophobic liquid collected from inside the housing construction. In certain preferred embodiments, the device further includes a second filter. Preferably, the second filter is placed within the housing construction and placed downstream from the coalescer filter. The gas flow management device is constructed and positioned to first direct the gas flow through the coalescer filter and then secondly to direct the flow of gas through the second filter, to the extent that the gas is directed inside and through the construction of the accommodation. Preferably, the coalescer filter has an upstream surface area not greater than 25% of a surface area upstream of the second filter. In certain preferred embodiments, the coalescer filter has an upstream surface area of about 0.1% -10%, typically about 0.5-1%, and preferably about 0.8% of a surface area upstream of the second filter . Preferably, the second filter comprises a folded medium. In certain devices, the second filter is removable and replaceable, and the housing is constructed and placed with an end cover that can be opened to gain access to remove the second filter without removing or removing the coalescer filter. The first and second filters can be mechanically connected to be replaced as a unit; or they can be separate constructions that can be replaced separately. In a preferred embodiment, the coalescer filter comprises a medium of nonwoven fibers having an average fiber diameter of less than 25 microns, typically and preferably within the range of 9-25 microns.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic view of an engine system using an aerosol separating device, in accordance with the present invention; Figure 2 is a schematic representation showing the application of the principles in a separating device according to the present invention; Figure 3 is a perspective view of a device according to the present invention; Figure 4 is a side elevational view of the device shown in Figure 3; Figure 5 is a cross-sectional view taken generally along line 5-5, of Figure 3, and viewed from a reverse direction to that shown in Figure 4; Figure 6 is a cross-sectional view taken generally along line 6-6 of Figure 3; Figure 7 is an exploded cross-sectional view of the device shown in Figure 5; Figure 8 is a fragmentary, exploded cross-sectional view of a portion of the device shown in Figure 6; Figure 9 is an enlarged perspective view of a coalescer filter shown in Figure 8; Figure 10 is a cross-sectional view, taken generally along line 10-10 of the figure figure l? is a top plan view of the device shown in Figure 3; Figure 12 is a bottom plan view of the device shown in Figure 3; Figure 13 is a side elevation view of the device shown in Figure 3, the view of Figure 13 is from a side opposite that shown in Figure 4; Fig. 14 is a side elevational view of the device shown in Fig. 3, the view of Fig. 14 is analogous to the view of Fig. 13, with the device of Fig. 13 having rotated 90 ° in the opposite direction to the hands of the clock, Figure 15 is a view of the device shown in Figures 13 and 14 wherein the view is a side elevational view showing the device that has rotated 90 ° in clockwise relation to the angle of view shown in Figure 13; Figure 16 is a fragmentary and enlarged cross-sectional view of a joint of the first and second sections, shown in Figure 5; Figure 17 is a perspective view of a second embodiment of a coalescer filter, according to the present invention; Figure 18 is a perspective view of the device of Figure 17 showing the opposite side, according to the present invention; Figure 19 is a top plan view of the device of Figure 18, showing a housing body and with the cover and the first and second stage filter means removed, in accordance with the present invention; Figure 20 is a side elevational view of the housing body shown in Figure 19, in accordance with the present invention; Figure 21 is a somewhat schematic view, in cross section, taken along line 21-21 of Figure 19 of the body, in accordance with the present invention; Figure 22 is a top plan view of the cover shown in Figure 18, and showing an interior surface of the cover, in accordance with the present invention; Figure 23 is a top plan view of the body holding the filter means of the second stage, in accordance with the present invention; Figure 24 is a top plan view of the filter body, analogous to that of Figure 23, but with the filter medium of the second stage removed, and showing the filter medium of the first stage placed in a region of entry, according to the present invention; Fig. 25 is a somewhat schematic cross-sectional view taken along line 25-25 of Fig. 29 of the filter medium of the first stage, according to the present invention; Figure 26 is a somewhat schematic, cross-sectional, fragmented view of an adapter member and showing a bypass valve device, in accordance with the present invention; Fig. 27 is a schematic, side elevational view of the filter means of the second stage, according to the present invention; Fig. 28 is a schematic view of an engine system using a filter device, in accordance with the present invention; Figure 29 is a top plan view of the construction of the first stage filter means, in accordance with the present invention; and Figure 30 is a side elevation view of the filter medium construction of the first stage shown in Figure 29, according to the present invention.

DETAILED DESCRIPTION I. A typical application - engine crankcase ventilation filter.

Pressure-charged diesel engines often generate "leakage" gases, that is, a flow of an air-fuel mixture that leaks past the pistons of the combustion chambers. Such "leakage gases" generally comprise a gaseous phase, for example air or gases that were not subjected to combustion, which transport therein: (a) petroleum or fuel aerosol comprising mainly 0.1-5.0 micrometer droplets; and (b) combustion carbon contaminants, which typically comprise carbon particles, most of which are approximately 0.1-10 microns in size. Such "leakage gases" are generally directed out of the engine block, through a leakage outlet. In the present, when the term "hydrophobic" fluid is used with reference to the liquid aerosol entrained in a gaseous flow, the reference means non-aqueous fluids, especially oils. Generally, such materials are immiscible in water. Here, the term "gas" or variants thereof, used in connection with the carrier fluid, refers to air, gases that were not subjected to combustion or other carrier gases for the aerosol. The gases can transport substantial amounts of other components. Such components may include, for example, copper, lead, silicone, aluminum, iron, chromium, sodium, molybdenum, tin and other heavy metals. Engines operating with such systems as trucks, farm machinery, boats, buses and other systems generally comprise diesel engines, and may have significant gas flows as described above. For example, flow rates and volumes in the order of 0-50 cfm are very common (typically from 5 to 10 cfm). Figure 1 illustrates a scheme indicating a typical system in which the coalescer / separator device according to the present invention could be used. With reference to Figure 1, a motor generally with the number 10 is shown. The motor 10 can generally comprise a diesel engine, although other types of engines are contemplated. The motor 10 supplies a leak gas, which can carry substantial quantities of oils carried therein as an aerosol, and also substantial amounts of fine contaminants, such as carbon contaminants. The leak gases are vented through the connector 12 and through a check valve 14. The check valve 14 can also be found upstream in the system. Attached to the housing for the check valve 14 is a connector 16. Downstream of the connector 16 and attached thereto is a filter 18 coalescer. The coalescer filter 18 separates the leakage gas into two components that include a liquid component and a partially filtered gas component. A second stage filter 20 is attached to the coalescing filter 18 by means of another connector 22. The filter 20 of the second stage acts to further purify part of the filtered gaseous component of the coalescer filter. That is, it removes fine particles which can still remain in the gaseous component. The purified gas is then directed through a connector 24 through a pressure regulator 26 into a motor pick-up system 28 such as a turbine. The liquid component of the coalescer filter 18 is directed through a line 30 into a collector 32 of the motor. In accordance with the present invention, there is provided a device for separating a hydrophobic liquid phase from a gas stream (sometimes referred to herein as a coalescer / separator device). When it works, a contaminated gas stream is directed into the interior of the coalescer / separator device. Within the device, the fine oil phase or the aerosol phase (ie, the hydrophobic phase) coalesces. The device is constructed so that the hydrophobic phase coalesces into droplets, it will drain as a liquid so that it can be easily collected and removed from the system. With the preferred devices as described in the following, the coalescer or coalescer / separator, especially with the oil phase in the charged part thereof, operates as a prefilter for carbon pollutant transported by the gas stream. In fact, in the preferred systems, as the oil is drained from the system, it will provide some self-cleaning of the coalescer because the oil will carry therein a portion of the trapped carbon contaminant. In the preferred devices according to the present invention, the coalescer / separator device is constructed with a removable media component for ease of cleaning or regeneration. In some preferred systems, at least a single downstream filter (or second filter) or polishing filter is provided. In other systems, multiple downstream filters can be provided. The general principles of operation of a system according to the present invention will be understood with reference to the scheme of Figure 2. In Figure 2, there is shown a flow of gas to be filtered, directed into the interior of the system 49 in the number 50. With number 51 a coalescer or coalescer / filter is usually indicated.

As the air passes through the coalescer 51, two streams of material are generated; a stream 52 of a little filtered or purified gas; and a liquid phase 53. The gaseous stream 52 is shown directed towards a second stage polishing filter 55, with a gas outflow from the indicated device via line 56. At this point, the gas can be directed to the downstream equipment or to the atmosphere. In typical systems such as that shown in Figure 1, the gases in line 56 can be directed to an engine inlet system. In other typical systems, the gases in line 56 can be directed to the atmosphere or to the exhaust. The liquid phase (with any entrained solid) of the coalescer 51 is shown directed via line 53 to a drainage construction 59. The material is then routed via line 60 whenever desired. For example, it can be recycled to the Crankcase to be used. Alternatively, it can be collected separately for disposal. In general, coalescer 51 comprises material in which fine oil droplets transported within air 50 will tend to collect and coalesce into droplets. Useful materials and constructions for this are described below.

In general, preferably the support or substrate material in the coalescer 51 is selected and configured in such a way that the combination of the coalescer 51 and the collected oil droplet phase will operate as a prefilter for contaminants (especially carbon particles) carried as well. on line 50. The contaminants or carbon particles will tend to be entrained in the liquid flow, leaving the system through line 53. Thus, to some extent, in a system such as the one described herein, the coalescer 51 is self-cleaning. In other words, the continuously collected oil phase will tend to wash part of the phase of carbon particles continuously collected out of coalescer 51. For typical systems, coalescer 51 is anticipated to be designed so that with a typical gas flow through it, a substantial life for the coalescer 51 will result, in part, from the washing effect. However, it is also anticipated that the system will not be "tuned" with an effort towards optimal operation through self-cleaning. It is anticipated that the coalescer 51 will be configured, in the preferred systems, for periodic regeneration resulting from the removal of the filter medium or coalescing material placed therein and either cleaning or replacement. Stated otherwise, it is anticipated that in typical applications, the material (medium) of the coalescer will be chosen with a focus on obtaining a high efficiency aerosol removal, preferably at least 20%, more preferably at least 25-50% by weight, when used in a typical way. This will also result in a substantial removal of the carbon particles. The removal of carbon particles will be partly facilitated by the fact that substantial amounts of the oil phase will coalesce into the medium, and that the oil phase will help trap carbon material. It is anticipated that if the coalescer material is selected (tuned) to obtain the highest removal efficiency of carbon particles, especially in the order of approximately 60%, a great restriction to the flow of gases may also be offered, which is completely desirable as a coalescer filter.

II. An example of a multi-layer oil aerosol separator The attention is now directed in Figures 3-15, in which a multi-layer oil and aerosol separator or a coalescer / separator according to the present invention is provided. The system is generally referred to herein as "multi-stage" because it not only includes an aerosol separator / filter device according to the present invention., if not. which also includes at least one only, and may include several second stage or downstream filters, for further purification of the air stream. The oil separator or coalescer / separator devices as generally described herein may alternatively be used in total assemblies that do not include downstream filters. In Figure 3, a perspective view of the double-stage aerosol separator assembly 75 is provided. In general, the first separation stage, which comprises a coalescer filter, is indicated generally with the number 76 and the second stage, which comprises a polishing filter, is located within the portion of the assembly indicated generally with the number 77. With reference to Figure 3, the assembly 75 includes a housing 80 having an input tube construction 81; a receptacle portion 82; and an outlet tube construction 83. When used, the gas flow to be modified is directed into the interior of the receptacle portion 82 by means of the inlet tube construction 81. The liquid which coalesces within the first stage 76 is drained to the bottom portion 85 of the receptacle portion 82, from which it is removed as described in the following. The gas phase is directed through the receptacle portion 82, and a filter element positioned therein, and directed outwardly from the assembly 78 through the outlet tube construction 83. For the assembly 75 shown, the inlet tube construction 81 comprises a segmented tube construction 88 (Figure 8). The term "segmented tube construction" and variants thereof as used herein, refers to a tube which comprises at least two separable segments mechanically fixed together. That is, the segments can easily be separated from each other. In the case of the segmented tube construction 88, two segments are shown comprising a first segment 90 and a second segment 91. The segment 91 is completely separable from the remainder of the assembly 75, while the segment 90 is integrally formed with a portion of the housing 80. In the device shown, the coalescer separator of the first stage or filter is positioned between the first segment 90 and the second segment 91. The. second segment 91 is fixed, in fluid flow relation, with the first segment 90, by a clamp device 95. The clamp device 95 comprises an over sleeve 96, secured to be sealingly attached to the segments 90 and 91, by clamps 97 and 98. The clamps 97, 98 include bands 102, 103 mounted around the over sleeve 96 and which are secured With fasteners 137, 138. Therefore, the second segment 90 can be removed and replaced simply by loosening the clamp 98. Even with reference to Figure 3, the housing 80 comprises a first cover section 104 and a second section 105 or lower section. The two sections are joined together along the seam 107 by the bracket 108. For the device shown, the sections 104 and 105 can be separated from one another, selectively, simply by loosening or releasing the bracket 108. This allows access to the interior of housing 80, to provide service. Even with reference to. Figure 3, for the particular device shown, the cover section 104 is a molded plastic construction 109; and a lower section 105 which is a section 110 of metal foil. Although alternative devices are possible, the advantages of constructing the two sections 104 and 105 as described will be apparent from the following descriptions. When used, the device 75 can be easily mounted to a frame of a vehicle or other equipment. Various mounting devices can be used including mounting band devices or a frame with appropriate retaining nuts. In some cases, molded mounting devices can be constructed to extend around the outer periphery of the cover section 104, to allow a greater choice of radial placement, during assembly. Before a detailed description of the internal components of the device 75 is presented, a review of some of the other figures will be performed in order to examine out the visible features of the assembly 75. Referring first to Figure 4, it is noted that the second section 105 or lower section has a lower end in the form of a bowl or funnel or a cover 120 end which places centrally the drained liquid 121 in it. The 120 bowl and drained bowl combination 121 comprises a collection and drainage device for hydrophobic liquid. When used, as the liquid coalesces within assembly 75, it will drain down toward the end of the plate or bowl 120, and will be directed by funnel toward drainage 121. Typically, drainage lines appropriate to drainage 121 will be secured to direct the collected liquid, as desired, for example to an oil collector. Also with reference to Figure 4, a further detail with respect to the bracket 108 is visible. The bracket 108 includes a metal band 125 having opposed end brackets 126 and 127 thereon. A turning key 128 includes a handle 129 which can be rotated to tighten the band 125 by pulling the ends 126 and 127 together.

In doing so, due to the configuration of the band 125 and certain components placed therein, discussed in the following, the housing sections 104 and 105 can be sealed together. Now turn attention to Figures 11 and 12.

Figure 11 is a top plan view of the device shown in Figure 3; and Figure 12 is a bottom plan view of the device. With reference to Figures 11 and 12, it is noted that the construction 81 of the inlet tube is mounted in the center of the housing 75. The housing section 104 of the housing generally has a circular outer wall 132. The circular outer wall defines a circular inner wall 133, FIG. 6. In general, the inlet tube construction 81 directs air passing therethrough, in the general direction indicated by the broken arrows 135, FIG. 11. alternative construction, the inlet tube can be mounted with a side wall thereof generally tangential to a circular inner wall of the housing, instead of directly to the central point or axis. A tangential assembly of the inlet tube in relation to the housing will create a tangential airflow path around the element.

Now the attention is directed "to Figure 6. Figure 6 is a cross-sectional view taken generally along line 6-6 of Figure 3. As a result of the orientation of the view in Figure 6, one observes the inner construction of the cover section 104 and the construction 88 of the segmented pipe With reference to Figure 6, the cover section 104 includes therein a circular deflection member 145. The deflection member 145 is placed separately of the outer wall 133, generating a cyclonic air flow conduit 146 therebetween.The outlet tube 83 includes an extension 147 concentrically aligned with and delimited by the deflection member 145. As will be understood from the Descriptions in the following, between section 147 and a deflection member 145, typically one end of the filter element (described in relation to Figure 5) is used in use Typically, the def member 145 The length will be about 75% -125%, more typically about 110% of the inlet diameter. Still with reference to Figure 6, the structures 150 comprise bays in the lower section 105, discussed below. Even with reference to Figure 6, for the particular device shown, interposed between the second section 91 and the first section 90 of the construction 88 of the segmented tube includes a filter 150 coalescer therein. The coalescer filter 150 is fixed within the frame 151 tangentially through the gas flow conduit 152. Therefore, the gas that passes from the region 153 to the tube 90 in the region 154, of the tube 91, generally passes through the coalescer filter 150. Of course, the coalescer filter 150 can be placed in other parts of the assembly 75; for example, in tube section 91 or in cover 104. However, the device shown is convenient and effective. The coalescer filter 150 comprises a material suitable for coalescing hydrophobic aerosol conveyed within a gas stream passing through the tube 91 into the housing 80. Preferred materials for the coalescer filter 150 will be described below. It is anticipated that in typical embodiments, the coalescer filter 150 will comprise a nonwoven fibrous assembly. Now turn attention to Figure 8. The number 160 is segment 160 removable and replaceable. The segment 160 includes an appropriate frame 161, 162 for securely receiving the coalescer filter 150 therein and for positioning the coalescer filter 150 in locking relationship between the first section 90 and the second section 91.

The coalescer filter 150 is preferably sealed within the frame 161, 162. The sealing can be carried out by gluing, compression, heat stacking, ultrasonic welding or by other methods and materials. Preferred constructions are described below. It is noted that for the device shown in Figure 8, the flow conduit 153 is approximately of cross sectional diameter equal to the diameter of the cross section of the region 154. In general, it is desirable to maintain a frontal velocity of approximately 102-254 cm / sec (200-500 feet / min), preferably about 178 cm / sec (350 feet / min) through the coalescer 150. Now the attention is directed to figure 9, in which a perspective view of the coalescer filter 150 within its frame 161, 162. With reference to Figure 9, the coalescer segment 160 is generally cylindrical in shape. It includes a face 155 upstream, a face 156 downstream on an opposite side thereof. With reference to Figure 6, in use, as the gas flow is directed through the coalescer filter 150 from the region 153 to the region 154 (and to the housing 80), the hydrophobic liquid carried or entrained within the gas flow, as an aerosol, it will coalesce within the filter 150. As liquid droplets form, they will drain from the filter 150 and, due to the gas flow, will generally flow outwardly from the filter 150 in the direction indicated by the arrows 179. The "gas flow" will generally cause the flow of liquid between the housing 80 and drain downwardly from the wall 133 inward, toward the interior or bottom of the cover 105. Finally, the liquid will drain to the bottom of the housing. the cover 105, along the end plate 120, towards the drain 121, figure 4. This flow of liquid will include therein some particulate material, for example, carbon particles, trapped within a liquid. in the coalescer 150. Therefore the flow of the liquid, to some extent, will self-clean the filter 150. On the other hand, the gas flow will enter * the housing 80 in a cyclonic pattern, between the deflector 145 and the interior wall 133 . This gas flow is then directed to a second stage filter, described later in relation to Figures 5 and 7. With reference to Figure 5, assembly 75 is shown in "cross section." It can be seen from Figure 5 that the assembly 75 includes a downstream or second stage filter element 170 positioned therein Preferably the element 170 is removable and replaceable The element 170 generally comprises a filter means 171 positioned between the inner and outer liners 172 and 173. A preferred construction and material are described below, The element 170 includes a closed end cap 174 and an open end cap 175. The open end cap 175 includes a radial sealing portion 176 sized and configured to sealingly engage the seal. section 147 of tube, in a radially sealing manner along the same As a result, the material in region 176 is compressed between tube 147 and other porc ions of the element 171 to form the radial seal. When used, after the gas flow enters the cyclonic section 143, it passes downwards in the general direction indicated by the arrows 176, 177 through the filter element 170, and outwards, through the tube 83 of departure. The filter element 170 generally operates as a polishing filter to remove materials such as apart from the aerosol that may have passed the coalescer, smoke and hydrocarbons from the gas flow stream. The flow of liquid coalesced from the coalescer 150 will again cause a run down along the interior wall 133 in the section 105, and down along the surface 183 of the wall toward the drainage 121. . Thus, this liquid will generally not be directed to the first filter element 170. Attention is now directed to Figure 10. Figure 10 is a cross-sectional view taken generally along line 10-10, Figure 5. From the comparison of Figures 5 and 10, it can be understood that section 105 includes lower spans 185 therein. For the device shown, a plurality of (4) spans 185 is present. The spans 185 coincide on the drain 121 and provide a reinforcement structure in the bottom 120 to lightly support the filter element 170 in compression against the surface 186 and above the liquid (which can accumulate in the upper part of the end cover 120, during use). In general, the openings 185 separate the filter element 170 from the oil that is collected. The openings 185 also help force the element 170 to place it in the housing and keep the seal 176 in place. The openings 185 also help to ensure that the element 170 does not fall out of the housing during use due to vibration. In the illustrated embodiment, the spans 185 are molded separately as a separate part of the housing, and then connected to the housing by an appropriate fastener 122. Now we turn our attention to figures 7 and 16.

The cover 104 includes a lower flange 189 with a packing recess 190 therein. The packing recess 190 is sized and configured to receive, partially placed thereon, an O-ring 191. The section 105 includes a matching shoulder 193. When the device is assembled, the flange 193 is compressed towards the flange 189, with the ring at 0191 placed between them. The shape of the inner surface 197 of the band 195 is configured so that as the key 128 is tightened, the band 195 compresses the flanges 189 and 193 together, around the ring at 0 191, which generates a good seal. To facilitate this, the interior surface 197 generally has a shape similar to a wave or the letter O. Figure 16 shows the flanges 189, 193 held together by the band 195. For the particular preferred device shown, it is noted that the area surface upstream of the coalescer filter 150 is substantially smaller than a surface area upstream of filter element 170 of the second stage. Especially if a grooved medium is used for the medium 171, this difference can be substantial. It is anticipated that by using the preferred materials described herein, a system in which the coalescing filter 150 having an upstream surface of about 1-20% and not more than 25% of the area downstream of the medium 171 will be effective. Here, the term "gas flow management device" or variants thereof will sometimes be used to refer to portions of devices which direct the flow of gas. For the device 75, figures 3-15, this will include the inlet tube, the walls, the reflectors and the outlet tube. The "gas flow direction device" generally operates to ensure an appropriate gas flow, through the filters, in the proper order. The constructions according to the present invention can become rather small, although highly efficient. The materials and dimensions to accomplish this are described below, for a variety of systems.

III Some useful materials A. Coalescing media An important advantage can be obtained by the choice of a certain preferred material for the coalescing medium. Preferred materials comprise fibrous nonwoven constructions of fibers of appropriate size, and with appropriate strength or density, to function as good coalescers for the types of air streams that are likely to be encountered when used. Preferably, organic fibers such as polyester fibers, of a denier of about 1.5 or a diameter of about 9-25 microns, typically about 14.5 microns, are used to form the material. A preferred material is 8643, available from Kem-Wove, Inc., Charlotte, North Carolina 28241. • The density or percent strength of the medium may vary, based on the particular use. In general, the solidity percent, in the free state, is approximately 1.5-1.8.

B. Filter medium downstream For the downstream filter, the conventional means used in such devices as diesel engines will be acceptable for typical systems. One such preferred means is a folded paper of high surface loading. One such typical means is a high surface load folded paper having a weight of approximately 53.5 +/- 3.6 kg / 278.7 m2 (118 +/- 8 pounds / 3000 square feet); a permeability of approximately 0.325 +/- 0.03 m / s (34 +/- 5.5 feet per minute); a thickness at 8618 Pa (1.25 psi) of approximately 1.27-1.78 mm (0.05-0.07 inches); a tensile strength of at least 232 kg / m (13 pounds per inch); a wet discharge resistance of at least 2100 N / m (12 psi); and a cured wet discharge resistance not greater than 275,790 Pa (40 psi). Such means as used in a device as described herein provide an efficiency of at least 80% by weight.

C. Other components Preferably, the cover section of the housing is constructed of plastic, for example nylon filled with glass. The lower section is a metal sheet. Alternatively, the entire housing can be constructed entirely of metal or all of plastic. Preferably, the end caps are made of a polyurethane foam. Alternatively, the end caps can be made of metal.

IV. Principles in relation to the size of the system It is particularly advantageous that a device using the principles described herein can be configured in a relatively small package, with a highly efficient operation. For example, it is anticipated that a system such as that shown in the figures may be configured with a total size of approximately 12.7 cm (5 inches) in diameter and approximately 30.5 cm (12 inches) in length, with a total operating efficiency of 90% for gas flow streams such as a diesel leak combustion aerosol. A key component in such systems, of course, is the coalescer. In particular, the coalescer is configured to have an upstream surface area no greater than about 20%, typically not more than about 10% (usually 0.5 to 1%) of the surface area of the downstream filter medium. An example of a usable coalescer filter having an upstream surface area of approximately 0.002 square meters (3.75 square inches). The total volume is approximately 30.7 cubic centimeters (1,875 cubic inches), with a length of about 6.4 cm (2.5 inches), a width of 3.8 cm (1.5 inches) and a thickness of 12.7 mm (0.5 inches). The flow velocity is typically 0.002-0.004 m3 / s / (5-10 cfm), and the flow velocity is typically 1.0-1.9 m / s (3.2-6.4 feet per second). Means such as denier polyester fibers of about 1.5 and a diameter of about 14.5 microns used in a system such as that described herein, provide an aerosol removal efficiency of at least 25% by weight. The downstream filter medium such as that illustrated with the numeral 171 may be configured to have a diameter of approximately 8.9 cm (3.5 inches), and a length of approximately 17.8 cm (7 inches). The inner diameter, this, the diameter of the opening to receive the outlet tube construction, is approximately 5.1 cm (2 inches). The total area of the cylinder is approximately 0.05 m2 (76 square inches), and the surface area is approximately 0.25 m2 (390 square inches). A typical flow velocity is approximately 0.002-0.004 m3 / s (5-10 cfm), and a typical flow velocity is approximately 0.009-0.02 m / s (0.03-0.06 feet per second).

V. One additional modality Now the attention is directed to the additional modality shown in figures 17-30. With reference to Figure 17, the construction of the coalescer filter with the reference number 200 is shown. The coalescer filter construction 200 includes a housing 203. The generally mounted housing 203 is a rectangular box, which represents a convenient shape for certain uses, as characterized in the following. The housing 203 shown has a two-piece construction. More specifically, the housing 203 comprises a cover or door 205 mounted on the body or casing section 206.

With reference to Figures 17 and 18, the housing 203 includes the following three flow orifices: the gas flow inlet orifice 210; the gas flow outlet orifice 211; and the outlet orifice of liquid flow or drainage 212 of liquid. As a result, the coalescer filter construction 200 is configured in accordance with the general scheme of Figure 2. The attention is now directed to Figures 19-21. In figures 19-21, the body 206 of the housing is shown. The body 206 includes an upper wall 215 with a lower wall 216, a first side wall 217, as a second side wall "218, a rear wall 219. The walls 215, 216, 217 and 218 extend around and project from the periphery of the back wall 219, to form the receptacle construction 221. When used, the various filter devices described below are placed inside the receptacle 221. Attention is now directed to Figures 17 and 19-21. From these figures, it can be seen that the rear wall 219 includes a front side 224, which forms an inner surface of the receptacle 221; and on the rear side 225, which forms a rear and outer surface of the receptacle 221. Referring to Figures 17 and 19-21, the gas flow inlet orifice 210 is positioned to extend within the rear side 225 or wall rear 219. More specifically, the gas flow inlet hole 210 is directed into the receiver 228 (Figure 21). Receiver 228 defines a volume 230 that projects outward from the selected portions of rear side 225 or rear wall 219. Volume 230 is sized to receive a coalescer filter 233 (FIG. 29) therein. The inlet port 210 is directed into the volume 230, in order to direct the flow of gas entering the interior of the coalescer filter construction 200 through the coalescer filter 233, in the manner described in the following. In general, it is anticipated that, when used, the pressures within the interior 236 of the coalescer filter construction 200 may be in the order of approximately 6894 Pa (1 psi), typically approximately 6894-20684 Pa (1-3 psi). ) (approximately 10-15 inches of water). In addition, due to the nature and properties of the diesel fume gases, a haze of entrained oil is obtained, which may have a tendency to attempt to sweep from the filter construction 200. Therefore, a secure and good retaining door 205 is used in body 206. Attention is drawn to Figures 18 and 22 with respect to this.

With reference to Figure 22, the door 205 includes a hinged tab 240 and 241 formed integrally therewith. The hinged tabs 240 and 241 are sized to be received within the receivers 243 and 244 (FIG. 23), respectively, when the door 205 is mounted on the body 206. The receivers 243 and 244 allow the tabs 240 and 241 respectively to rotate. , so that the door 205 oscillates between an open and a closed position. When the door 205 is in a closed position of FIGS. 17 and 18, the receivers 243 and 244 secure the tongues 240 and 241 hinged firmly, so that along the edge 247 (FIG. 22), the door 205 can not be moved. easily separate from body 206 even under internal pressures of leakage gases in the order of 3447 to 6894 Pa (0.5 to 1.0 psi). The internal pressure of the leakage gases results in rather substantial forces on the gate 205, in the order of approximately 68947-275,790 Pa (10-40 psi), often approximately 3700 Pa (35 psi). The door 205 includes an opposite side edge 248, from the edge 247. Along this edge, the door 205 includes retaining tabs 250 and 251 aligned with the retaining tabs 253 and 254 respectively on the body 206. The tabs 250 and retainer 251 include openings 256 and 257 respectively thereon, overlying analogous openings 253a and 254a and tabs 253 and 254 respectively. Preferably, the openings include insertion of threaded material to prevent wear and bleeding of the threads. To secure the closed door 205, the coalescer filter construction 200 includes bolts 260 and 261 of butterfly (figure 18) extending through openings 256 and 257, respectively. After the door 205 is properly positioned, it can be locked closed by the threaded butterfly bolts 260 and 261 for the tabs 253 and 254 until the butterfly bolts 260 and 261 descend. A gas flow seal between the door 205 and the body 206 is provided by a gasket 265, figures 23 and 27, as described in the following. Even with reference to Figures 17, 19 and 20, note that the lower wall 216 of the housing 203 is somewhat funnel-shaped downward, towards the drainage 212 of the lower central liquid. Also note that the gas flow outlet orifice 211 extends outwardly from the door 205 (Figures 18 and 22). Note that the outward gas flow through the outlet orifice 211 is directed generally orthogonal to the direction of the inflow through the inlet orifice 210. Although alternative constructions may be used, this is preferred for certain embodiments because it is convenient and minimizes the space occupied by the housing 203. In certain preferred embodiments, the drain 212 includes a one-way valve to allow drainage of the liquid, but not the entrance of liquid. Referring again to Figure 17, note that the rear wall 219 defines openings 301, 302, 303 and 304 therein, located at each respective corner of the body 206. Preferably, the openings 301-304 include threaded metal inserts to avoid the wear and sweep of the threads. The openings 301-304 are provided to allow the filter construction 200 to be fixed in a convenient position, for example in a motor. The filter construction 200 itself is very flexible in its position. For example, the housing 203 can be mounted remotely from the engine crankcase at locations anywhere to which a hose can be directed. For example, the housing 203 can be mounted on a fire wall, or in a frame, and can be mounted above the oil collector. Preferably, the housing 203 is mounted no more than 4.6 m (15 feet) away from the engine. Even with reference to Figure 17, note that the body 206 is constructed and positioned to receive an adapter construction 310. The adapter construction 310 includes a filter housing 311 and a valve housing 312.

Projecting outward from the filter housing 311 is an inlet tube 313, which generally circumscribes the gas flow inlet orifice 210. Each of the filter housings 311 and 312 comprises circular members extending outward from a surrounding flange member 315. The adapter construction 310 is securely received by the body 206 and is attached to the rear side 225 of the rear portion 219. Methods such as ultrasonic welding attach the body-adaptive construction 310. 206. The valve housing 312 is for retaining a bypass valve construction 285 therein, as further described in the following: In general, housing 203 includes, encased therein, two filter constructions: an upstream coalescer filter 233 and a downstream panel filter 268. In some embodiments, the coalescer filter 233 and the panel filter 268 will comprise separate pieces which are placed separately within the housing 203. In other embodiments, the coalescer filter 233 and the panel filter 268 can be constructed together that both are inserted and removed from the housing 203 in a single and simultaneous operation In the mode shown, the filter 233 coal The scener and the panel filter 268 are separated, as members or independent constructions.

With reference to Figures 23 and 27, the panel filter 268 comprises folded means 270, placed in a generally rectangular configuration. The medium 270 is circumscribed by the outer rectangular package 265. The panel filter 268 includes a front facing or screen 271. The front screen 271 is actually positioned on a downstream side of the medium 270 and helps retain a rigid medium configuration. A variety of materials can be used for the open or porous screen 271, for example, perforated metal, expanded metal or plastic constructions. In general, plastics such as glass filled nylon will be preferred for the reasons described below. In Figure 23, the screen 271 is shown partially exploded from the downstream medium 270. It should be untood that, in the preferred embodiments, the screen 271 extends over the entire surface within the perimeter of the package 265. The package 265 may comprise a variety of moldable polymeric materials to form an appropriate packaging member, with the medium 270 positioned in the same. A useful material is polyurethane such as that described in commonly assigned U.S. Patent No. 5,669,949 for end cap 3, incorporated herein by reference. Packaging material 265 includes the following polyurethane, - processed to a final product (soft urethane foam) having a "as molded" density of 0.22-0.35 g / cm3 (14-22 pounds per cubic foot (lbs / ft3)) and which shows a smoothness so that deflection at 25% requires approximately a pressure of 68947.57 Pa (10 psi). In some embodiments, the density "as molded" varies from 1.1-1.7 g / cm3 (14-22 pounds / cubic foot) of interval. The polyurethane comprises a material made with I35453R resin and isocyanate I305OU. The materials should be mixed in a mixing ratio of 100 parts of resin 135453 to 36.2 parts of isocyanate I305OU (by weight). The specific gravity of the resin is 1.04 (8.7 pounds / gallon) and for the isocyanate it is 1.20 (10 pounds / gallon). The materials are typically mixed with a high dynamic shear mixer. Component temperatures should be 21-35 ° C (70-95 ° F). Molding temperatures should be 46-57 ° C (115-135 ° F). The resin material I35453R has the following description: (a) average molecular weight. 1) polyether base p'oliol = 500-15,000 2) diols = 60-10,000 3) triols = 500-15,000 (b) average functionality 1) total system = 1.5-3.2 (c) hydroxyl number 1) total systems = 100-300 (d) catalysts 1) amine = Air Products 0.1-3.0 PPH 2) tin = Witco 0.01-0.5 PPH (e) surfactants 10 1) total system = 0.1-2.0 PPH (f) water 1) total system = 0.03-3.0 PPH (g) pigments / dyes 1) total system = 1-5% carbon black (h) blowing agent 1) 0.1-6.0% HFC 134A 20 The description of isocyanate I305OU is as follows (a) NCO content - 22.4-23.4% by weight (b) viscosity, cps at 25 ° C = 600-800 25 (c) density = 1.21 g / cm3 at 25 ° C (d) initial boiling point - 190 ° C to 5 mm Hg (e) vapor pressure = 0.0002 Hg at 25 ° C (f) appearance - colorless liquid (g) flash point (closed Densky-Martins container) = 200 ° C Materials I35453R and I305OU are available from BASF Corporation, Wyandotte, Michigan 48192. Preferably, body 206 includes a perimeter channel 272 therein (Figure 19), sized and configured to receive package 265. Figure 23 shows the filter 268 of panel housed within channel 272 and retained by body 206. Figure 23 depicts an observed view when door 205 of body 206 is opened. Sealing is provided between door 205 and body 206 when compressing packing 265 within of the perimeter channel 272 as the door 205 is closed. In Figure 23, the panel filter 268 is illustrated with an optional handle structure to assist in removing the panel filter 268 from the channel 272 in the body 206. In the example Particularly illustrated, the handle structure includes a pair of handles or pull tabs 278, 279. The pull tabs 278, 279 are attached to the screen 271 and can rotate between a collapsed position adjacent the screen 271, and a vertical position, in extension from the. screen 271. The pull tabs 278, 279 are preferably constructed of a non-metallic material, so that they are incinerable. One such material is plastic, such as nylon filled with glass. In other embodiments, the panel filter 268 does not include a handle structure. The panel filter 268 is removable from the body 206 by holding the perimeter gasket 265, or the screen 271, or a combination of the two. In an alternative embodiment, the package 265 may comprise a foamed silicone. Foamed silicone can be useful, in circumstances where the internal temperature is high, such as for example higher than 99 ° C (210 ° F). Preferably, the panel filter 268 is dimensioned and configured so that the longitudinal folds 274 of the means 270 extend vertically, i.e., between the upper wall 215 and the lower wall 216, when the coalescer filter construction 200 is mounted for its use. The advantages which are derived from this indicated liquid flow are those described in the following. A useful material for medium 270 is a synthetic fiberglass filter medium, which is coated and corrugated to improve operation under conditions of an air / oil mist environment. The synthetic glass fiber filter medium can be coated with a low surface energy material, such as an aliphatic fluorocarbon material, available from 3M St. Paul, Minnesota. Before coating and corrugation, the medium has a. weight of at least 36.3 kg / 278 m2 (80 pounds / 3000 square feet); not greater than approximately 39.9 kg / 278 m2 (88 pounds / 3000 square feet); typically in the range of approximately (80-88 pounds / 3000 square feet) (136.8 + 6.5 grams per square meter). The medium has a thickness of 0.69 ± 0.10 millimeters (0.027 + 0.004 inches); a pore size of about 41-53 micrometers; a resin content of approximately 21-27%; a discharge resistance, wet machine 124 + 34 kPa (13-23 psi); a resistance to wet discharge after 5 minutes at, 149 ° C (300 ° F) of 255 ± 83 kPa (37 ± 12 psi); a discharge resistance ratio of approximately * 0.30-0.60; and a permeability of 10.1 + 1.8 meters per minute (33 + 6 feet per minute). After corrugation and coating, the medium has the following properties: a corrugation depth of approximately 0.58-0.69 millimeters (0.023-0.027 inches); a wet tensile strength of approximately 3.6 + 0.91 kilograms per centimeter (6-10 pounds per inch); and a dry discharge resistance after corrugation not less than 207 kPa (30 psi). The depth of the fold is arranged to be at least 5.1 cm (2 inches), not more than about 6.4 cm (2.5 inches) and typically about 6.3 cm (2.31 inches) from the tip of the outermost region of the package 265 The length between the crease tip and the innermost region of the package 265 is at least about 3.8 cm (1.5 inches), not more than about 5.1 cm (2 inches) and typically about 4.6 cm (1.8 inches). When part of an arrangement such as a coalescer filter construction 200, the medium 270 has a front speed of at least about 0.05 cm (0.1 feet / minute), not more than about 2.5 cm / sec (5.0 feet / minute), and typically in a range of approximately 0.05-2.5 cm / sec (0.1-5.0 feet per minute). Preferably, there is a front speed of about 0.20 cm / sec (0.4 feet per minute). The attention now goes to the filter 233 coalescer. The coalescer filter 233 comprises a fibrous polyester medium 322 oriented in a generally circular configuration. Attention is drawn to Figures 25, 29 and 30. The means 322 is maintained and encapsulated by a frame or housing construction 378 that includes a first and second matching housings 324, 325. The housing 325 is circumscribed by a O-ring outer or packing 327. The coalescer filter 233 includes a pair of supports, coatings or screens 320, 321. The screens 320, 321 are placed on both sides, upstream and downstream of the means 322, and help retain the configuration of the rigid medium. Various materials can be used for open or porous screens 320, 321, for example perforated metal, expanded metal or non-metallic materials such as plastic constructions. In general, non-metallic materials such as plastics, ie, glass filled nylon, will be preferred for the reasons described below. An O-ring gasket 327 provides a seal between the receiver 228 in the body 206 and the coalescer filter 233. Figure 24 shows the coalescer filter 233 housed within the receiver 228 and the housing 311. The O-ring gasket 327 is compressed between and against the coalescer housing 325 and the housing wall 311 to form a radial seal therebetween. In an alternative embodiment, the O-ring gasket is sealed between and against the housing 325 and the receiver 328. In the illustrated embodiment, the housings 324, 325 are constructed of a rigid non-metallic material, such as plastic, for example delrin. . In an alternative embodiment, instead of the matching housings 324, 325, there is a single or unitary molded housing construction, such as the ring molded around the means 322. In that embodiment, the unitary housing construction or ring is constructed of a compressible material, for example, foamed polyurethane 4, such as the foamed polyurethane which forms the perimeter gasket 265 of the panel filter 268 and which is described in U.S. Patent No. 5,669,949 for the end cap 3 , patent which is incorporated herein by reference. The specific polyurethane useful for the molded ring is described in detail above, with respect to the package 265, although the density "as molded" may vary a little, in certain embodiments, within the range of 1.1-1.7 g / cm3 ( 14-22 pounds / foot3). In this alternative modality, a module or patch of the medium 322 with the screens 320, 321 on both sides enclosing or encapsulating the means 322 are placed with respect to an appropriate mold, so that the polyurethane is molded around the module 322, and the screens 320, 321 This results in a compressible housing construction, preferably of circular configuration, molded around, retained and circumscribing the combination or modulus of the medium 322 and the screens 320, 321. In this construction, the polyurethane ring foamed and molded around the means 322 is compressible to be removably mounted within the housing 311 and the receiver 228. The ring is then compressed between and against the wall of the receiver 228 and the means 322 to form a radial seal therebetween.

Now turn the attention to figure 24. Note that means 322 is a circular patch. It is placed in the lower part of the coalescer filter 233 and oriented to be in the lower part of the window 330, formed in the body 206. The orientation of the means 322 in this position has advantages. For example, the coalescer filter 322 coalesces liquids, such as oil, from gaseous streams that come through the inlet hole 210 of the gas flow. Due to the position of the means 322 at its lowest point in the window 330, liquid which coalesces to allow the displacement of the sweep removal means 322 on the housing 324, and within the funnel-shaped bottom wall 216 to drain 212 of liquid. In Figure 25, note that the uniform flanges 332, 333 of the housing 324, 325. This shape helps drain the liquids that have coalesced into the medium 322. Furthermore, when comparing Figures 19 and 24, it is readily apparent that the means 322 is located outside the direct force of the displacement flow through the gas flow inlet orifice 210. By this arrangement, the housing 324 acts as a baffle to protect the medium 322 from the direct force of the gas flow from the inlet orifice 210. The coalescer filter 233 is shown in the illustrated embodiments as circular with a circular patch positioned eccentrically of the means 322. That is, the circular patch of the medium 322 is positioned offset or unfocused within the housing construction 378. However, the coalescer filter 233 can have various shapes and sizes. For example, the housing construction 378 need not be circular, but may have other configurations. The medium 322 need not be circular, but may have other shapes, such as rectangular, extending across the entire length of the diameter of the housing construction 378. The additional means 322 does not need to be placed in its eccentric position with respect to the housing construction 378. For example, the means 322 can be centered within the housings 324, • 325. However, the particular distribution shown in the figures is used because it is attractive, eye-catching and distinctive. The coalescer filter 233 is shown in a top plan view in FIG. 29. The opposite side of the coalescer filter 233 is a mirror image thereof. One type of material usable for medium 322 is a fibrous polyester medium. The material has an average fiber diameter of denier 1.5 (approximately 12.5 micrometers) and a strength in a free state of at least 0.85%. Typically, free-strength is less than about 1.05%. Typical free-strength solids are within the range of 0.85% -l.05 ??. It has a weight, typically greater than about 105 g / m2 (3.1 ounces per square yard). Typically it weighs less than 129 g / m2 (3.8 ounces per square yard). Typical weights are within the range of 105-129 grams per square meter (3.1-3.8 ounces per square yard). Typically, the medium has a compression thickness of 13.8 Pa (0.002 psi (free thickness) greater than about 0.32 inches). Typically, the medium has a compression thickness of 13.8 Pa (0.002 psi (free thickness) less than about 10.7 mm (0.42 inches)). The typical free thicknesses for the medium are in the range of 8.1-10.7 millimeters (0.32-0.42 inches).

The medium has a typical permeability of not less than about 113 meters per minute (370 feet per minute). In general, the coalescer filter construction 200 further includes a bypass valve construction 285 therein. The bypass valve construction 285 is provided in fluid flow communication with the volume 230 and the interior volume 336 of the housing 311 in a position upstream of the coalescer filter 233. This is provided by the duct 287, Figs. 17 and 26. The duct 287 is provided in fluid flow communication with the orifice 288 positioned adjacent the volume 230 between the coalescer filter 233 and the gas flow inlet orifice 210.

The bypass valve construction 285 further includes a bypass valve receiver 290, also in fluid flow communication with the duct 287, via the orifice 291. The orifice 291 is provided on an upstream side of the valve member 293 . The valve member 293 comprises a flexible diaphragm 294 sealed against the housing 295 and which is held or retained there against the spring 296 and a cup 297. A seal 338 is received by the receiver 290, and provides a support surface for the spring 296 against which it is compressed. On the side 298 downstream of the diaphragm 294 an output is provided 299 of gas flow bypass. A bore 340 is provided through the adapter construction 310 (figures 17 and 19). The bore 340 is in airflow communication with the opening 342 in the receiver 290. The bore 340 vents to the atmosphere, which is in air communication with the opening 342. The opening 342 provides an inlet in the volume 344 behind the diaphragm 294. Therefore, the volume pressure 344 is at atmospheric levels. In usual use, the gas flow outlet through the bypass outlet 299 is blocked by the diaphragm 294, under pressure from the spring 296. However, when the pressure within the duct 287 exceeds a designated limit, the pressure will be diverted. diaphragm 294 moving away from the housing 295 far enough to allow a gas flow directly to the bypass outlet 299 without passage through the coalescer filter 233. Therefore, the pressure must accumulate sufficiently inside the inlet hole 210, for example as a result of the restriction due to the coalescer filter 233 and / or to the panel filter 268 that are sufficiently occluded, a valve construction 285 The bypass will protect the seals of the motor and the equipment by allowing bypass ventilation through bypass outlet 299. Attention is now directed to Figure 28. Figure 28 shows a schematic diagram showing a possible application of the construction 200 of the coalescer filter of the present invention. Block 350 represents a turbocharged diesel engine. Air is drawn to the engine 350 through an air filter 352. The air filter or cleaner 352 cleans the air taken from the atmosphere. A turbine 354 extracts the clean air from the air filter 352 and pushes it to the engine 350. While in the engine 350, the air undergoes compression and combustion when coupled with pistons and fuel. During the combustion process, the engine 350 supplies leakage gases. The filter 200 is in gas flow communication with the engine 350 and clears the leakage gases. From the filter 200", the air is directed through the channel 356 and through the pressure valve 358. From there, the air is again pulled through the turbine 354 into the interior of the engine 350. A regulating valve or a valve 358 pressure regulates the amount of pressure in the engine crankcase 350. The pressure valve 358 opens more and more, as the pressure in the crankcase increases, in order to try to decrease the pressure to an optimum level. The pressure valve 258 closes to a smaller amount when it is desirable to increase the pressure inside the motor A check valve 360 is provided so that when the pressure exceeds a certain amount in the motor case 350, the check valve 360 It opens to the atmosphere, preventing damage to the engine.

A. Example of operation In operation, the coalescer filter construction 200 operates as follows. Leakage gases from an engine crankcase are trapped or admitted through a gas flow inlet orifice 210. The gases pass through the coalescer filter 233. The coalescer filter 233 separates liquids, with any entrained solid, from the rest of the gas stream. The liquid flows separating from the medium 322, on the housing 324, along the front side of the rear wall 219, along the bottom wall 216 funnel-shaped and downward, through a drain 212 of liquid. This liquid material is often an oil, and can be recycled to the crankcase to be reused. The gas stream which does not coalesce through the coalescer 233 continues on the second stage filter or the panel filter 268. The panel filter 268 removes additional particles and solids from the gas stream. The panel filter 268 has vertical folds, so that the particles and any additional liquid is collected or agglomerated in the folds and falls or drains by gravity downward toward drainage 212. The gas then exits through the exit orifice 211 of gas flow. From here, the gases can be directed, for example, to the turbine of an engine intake system. When the coalescer filter 233 or the panel filter 268 becomes clogged or occluded, the pressure will fill the duct 287, which will apply a force on the diaphragm 294 against the spring 296. Finally, the force will move the diaphragm away from its housing 295 and allow the gas to flow through the bypass outlet 299. The coalescer filter and the panel filter 268 are shifted outward as follows. The door 205 is removed from the body 206 by unscrewing the wing bolts 260, 261. The door 205 is then released. rotates by means of the articulated tabs 240, 241 and the receivers 243, 244. The vision is then as shown in Figure 23. That is, the downstream side of the panel filter 268 is visible. In one embodiment, the panel filter 268 and the coalescer filter 233 with separate and independent members. Therefore, the panel filter 268 is removed from the body 206 and discarded. This can be done, for example, by means of clamping tongues 278, 279 and pulling the panel filter 268 from the channel 272. The person changing the filters afterwards has the vision as shown in figure 24. This is , the coalescer filter 233 is sealed in place within the receiver 228 and the housing 311. The coalescer filter 233 is then removed from the receiver 228 and discarded. A second new coalescer filter is oriented within the housing 311 and the receiver 328, as shown in FIG. 24. A packing between the coalescer filter and the receiver 228 forms a seal as the coalescer filter is properly installed. Next, a second new panel filter 268 is oriented within the perimeter channel 272 of the body 206. This is shown in Figure 23. The door 205 is then rotated on its pivot arrangement between the hinge tabs 240, 241 and the receivers 243, 244 to a closed position (figures 17 and 18). The butterfly bolts 260, 261 are rotated within the openings 253a, 254a and tightened to form a seal with the packing member 265 between the door 205 and the body 206.

When discarding the coalescer filter 233 and the panel filter 268, preferably these constructions consist of non-metallic material, at least 95% non-metallic, more preferably at least 98%, and typically 99% or 100% by weight of non-metallic material. When the screens 271, 320, 321 are constructed of non-metallic materials, such as plastic, and each of the coalescer filter 233 and the panel filter 268 is completely non-metallic, the coalescer filter 233 and the panel filter 268 are completely incinerable , leaving little waste. This provides a convenient and clean removal of the coalescer filter 233 and the panel filter 268, and does not occupy space in a landfill. In an alternative embodiment, the coalescer filter 233 and the panel filter 268 are joined or fixed together. In this embodiment, the removal of the panel filter 268 also removes the coalescer filter. The combination of the panel filter 268 and the coalescer filter 233 is removed from the body 206 and discarded (eg by incineration). A second different combination of filter 268 from fixed panel to filter 233 coalescer is inserted or placed or installed in body 206", by orienting coalescer filter 233 in housing 311 and receiver 228, and creating a seal therebetween. As this is done, the panel filter 268 is oriented within the perimeter channel 272. The door 205 closes on the body 206, and is pressed against the packing member 265. This forms a seal between the body 206 and the door. 205 B. A specific example A specific example of a coalescer filter construction 200 is described herein. Of course, a wide variety of arrangements and dimensions are included within the scope of the present invention. The coalescer filter 200 is useful in a 300 horsepower (224 kw) Caterpillar 3406B engine. The engine has a piston displacement of at least 14.0 liters, typically 14.6 liters, with six cylinders. And typically it requires at least 4.97 1 (35 quarts) of oil, and typically about 5.68 1 (40 quarts) of oil. The engine uses a Schwitzer turbine charger. The coalescer filter construction 200 is particularly applicable to turbine-charged diesel engines that have a power of at least 50 horsepower.

This can include tractors from class 2 to tractors of class 8 and older. Motors other than turbine-loaded diesel engines may have applications for the coalescer filter construction 200 of the present invention. For example, natural gas engines or gasoline engines can also use the filter construction 200. In preferred applications, coalescer filter construction 200 will be used for large motors, that is, engines of a class 8 size or higher. Typical air intake rates for class 8 or higher engines are at least 0.9 m3 / s (2000 cfm) and typically are 0.9-1.4 m3 / s (2000-3000 cfm). Medium-sized motors, this, motors of classes 6-8 can also be used with filter construction 200. Medium-sized engines of a 6-8 class have air intake rates typically of at least 0.5 m3 / s (1000 cfm); often not greater than 0.9 m3 / s (2000 cfm). A typical class 6-8 rated engine has an air intake speed of between 0.5-0.9 m3 / s (1000-2000 cfm). The. Smaller motors in the range of class 4-6 also have applications for 200 filter construction. Typical air intake rates for class 4-6 engines in which the filter construction 200 may be used are at least 0.5 m3 / s (1000 cfm); Frequently, air inlet velocities are no greater than 0.7 m3 / s (1500"cfm) .A small-sized engine (class 4-6) has air intake rates typically of 0.5-0.7 m3 / s (1000 -1500 cfm).

A filter construction 200 tested in accordance with the present invention that has operated for 600 hours at an efficiency of 87%, by weight of oil. The construction 200 operates for 600 hours until the crankcase pressure is increased from 7.6 cm (3 inches) of water to 12.7 cm (5 inches) of water. That is, there are 5.1 cm (2 inches) of water to work with. It must be understood that the internal pressure of the crankcase is specific to the application. In certain applications, such as systems in which there is not much dust or debris in the air, such as in marine systems, the crankcase may have a negative pressure (i.e., from about -5.1 to -7.6 cm (-2 to - 3 inches) of water). In other applications, such as systems where there is an abundant amount of dust or debris in the ambient air, such as dirt trucks or city buses, the crankcase has positive pressure. The filter construction 200 is flexible to allow it to operate either with positive crank pressures, such as those typically encountered in diesel trucks loaded with turbine or in dirt vehicles, or negative pressures, such as those found in engines. marine It will be understood that they are feasible and a wide variety of specific application configurations, using the techniques described herein. The following dimensions are typical examples. The intervals are preferred because they have been satisfactory for the job, without resulting in a larger or more expensive structure than necessary. Although intervals other than those discussed below are contemplated, the following are convenient and typical. The door 205 has a width between about 15.2-22.9 cm (6-9 inches), typically about 17.8 cm (7 inches). It has a length of between approximately 20.3-28 cm (8-11 inches), typically approximately 24.1 cm (9.5 inches). Door 205 has a depth of approximately 5.1-7.6 cm (2-3 inches), typically approximately 6.1 cm (2.4 inches). The gas flow outlet orifice 211 has a diameter of approximately 2.5 cm (1 inch) The body 206 has a width of at least . 2 cm (6 inches), no greater than about 22.9 cm (9 inches), typically about 15.2-22.9 cm (6-9 inches), and typically about 17.8 cm (7 inches). It has a length of at least about . 3 cm (8 inches), no more than about 28 cm (11 inches), typically about 20.3-28 cm (8-11 inches), and typically about 22.9 cm (9 inches). It has a depth of at least about 6.4 cm (2.5 inches), not more than about 10.1 cm (4 inches), typically between about 6.4-10.1 cm (2.5-4 inches), and typically about 8.1 cm (3.2 inches) . The drainage 212 has a diameter of at least 1.3 cm (0.5 inches), no more than about 5.1 cm (2 inches), typically between about 1.3-5.1 cm (0.5-2 inches), and typically about 3 cm (1.2 inches). inches). The window 330 has a diameter of at least 6.4 cm (2.5 inches), no more than about 7.6 cm (3 inches), typically about 6.4-7.6 cm (2.5-3 inches), and typically about 6.9 cm (2.7 inches). inches). When assembled together, door 205 and body 206 have a depth of at least 12.7 cm (5 inches), not more than 20.3 cm (8 inches), typically between approximately 12.7-20.3 cm (5-8 inches), and typically approximately 16.3 cm (6.4 inches). The panel filter 268 has a length that includes a gasket 265 of at least about 20.3 cm (8 inches), not more than about 28 cm (11 inches), and typically between about 20.3-28 cm (8-11 inches) , often approximately 22.9 cm (9 inches), has a width of at least 15.2 cm (6 inches), no more than approximately 20.3 cm (8 inches), and often approximately 17.8 cm (7 inches). The folded filter has at least about 40 folds, not greater than about 70 folds, typically about 45-60 folds, and specifically about 52 folds. Each of the folds has a crease depth of at least about 3.8 cm (1.5 inches), not more than about 7.6 cm (3 inches), typically within the range of about 5.1-6.4 cm (2.0-2.5 inches), and frequently about 5.8 cm (2.3 inches). The length of the fold is at least 17.8 cm (7 inches), not more than 22.9 cm (9 inches), typically within the range of approximately 17.8-21.6 cm (7-8.5 'inches), and often approximately 21.1 cm (8.3 inches). The folded filter 268 has a perimeter, circumferential area within a range of approximately at least 225 cm2 (35 square inches), no greater than approximately 484 cm2 (75 square inches), typically approximately 258-452 cm2 (40-70) square inches), and often approximately 271 cm2 (42 square inches). The folded medium 270 has a surface area upstream of at least about 0.9 m2 (10 square feet), not more than about 1.4 m2 (15 square feet), typically within a range of approximately 0.9-1.4 m2 (10- 15 square feet), and preferably approximately 1.1 square meters (12 square feet).

The coalescer filter 233 includes a housing with a circular outside diameter of at least 5.1 cm (2 inches), not greater than about 10.2 cm (4 inches), typically within a range of 5.1-10.2 cm (2-4 inches) , and typically approximately 7.6 cm (3 inches). The thickness of the coalescer filter 233 is at least about 1.3 cm (0.5 inches), not more than about 3.8 cm (1.5 inches), and typically within a range of 1.3-3.8 cm (0.5-1.5 inches), and preferably about 2.5 cm (1 inch). The diameter of the medium 322 is at least about 2.5 cm (1 inch), not more than about 5.1 cm (2 inches), and typically in a range of 2.5-5.1 cm (1-2 inches), and typically about 3.6 cm (1.4 inches). The thickness through the medium 322 is at least about 1.3 cm (0.5 inches), no more than about 1.8 cm (0.7 inches), and typically about 1.3-1.5 cm (0.5-0.6 inches) thick. The medium 322 comprises fibers having an average fiber size of about 12.5 micrometers and a solidity percent, in free state, no greater than about 1.05%. The "medium 322 has an exposed surface area upstream of at least 6.5 cm2 (1 square inch), not more than about 16.1 cm2 (2.5 square inches), typically about 6.5-16.1 cm2 (1-2 inches - is square) ), and typically approximately 9.7 cm2 (1.5 square inches) The coalescer filter 233 has an average upstream surface area of at least about 0.4%, not more than about 1.5%, typically within the range of about 0.5-1% , and typically about 0.8% of the surface area of the medium upstream of the folded medium 270. The adapter construction 310 has a distance between respective centers of the filter housing 311 and the valve housing 312 of at least about 7.6 cm ( 3 inches), no greater than about 12.7 cm (5 inches), typically about 7.6-12.7 cm (3-5 inches), and typically about 10. 2 cm (4 inches). Filter housing 311 has a diameter of approximately 5.1-10.2 cm (2-4 inches), typically approximately 7.9 cm (3.1 inches). The valve housing 312 has a diameter of about 7.6-12.7 cm (3-5 inches), typically 10.7 cm (4.2 inches). The inlet orifice 210 has a diameter of about 1.3-3.8 cm (0.5-1.5 inches), typically about 2.5 cm (1 inch). The bypass valve outlet orifice 299 has a diameter of approximately 2.5-5.1 cm (1-2 inches), typically 3.6 cm (1.4 inches). Receiver 290 has a diameter of 10.2-15.2 cm (4-6 inches), typically about 11.9 cm (4.7 inches). It has a total thickness of 1.3-2.5 cm (0.5-1.5 inches), typically about 2.8 cm (1.1 inches). The spring 296 has a diameter of about 1.3-2.5 cm (0.5-1 inches), typically about 2 cm (0.8 inches). It has an axial length in an uncompressed state of about 1.9-3.2 cm (0.75-1.25 inches), typically about 2.8 cm (1.1 inches). The diaphragm 294 has a diameter of approximately 11.4-13.3 cm (4.5-5.25 inches), typically approximately 11.9 cm (4.7 inches). Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention described herein. It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is the conventional one for the manufacture of the objects or products to which it refers.

Claims

CLAIMS Having described the invention as above, the content of the following claims is claimed as property:

1. A diesel engine leak recovery system, characterized in that it comprises: (a) a first stage coalescer filter comprising a medium of nonwoven fibers; (i) the fibrous medium has a first surface area upstream; and (b) a second stage filter element placed downstream from the coalescer filter; (i) the filter element of the second stage comprises a folded medium and has a second surface area upstream; (ii) the first current surface area above the coalescer filter means is no more than 25% 'of the second surface area upstream of the middle of the filter element of the second stage.

2. A diesel engine leak recovery system, characterized in that it comprises: (a) a first stage coalescer filter comprising a medium of nonwoven fibers; (i) the coalescer filter of the first stage includes an outer periphery having a seal member positioned lengthwise; (A) the seal member for creating a seal with a housing construction, when the coalescer filter of the first stage is operably placed in the housing construction; and (b) a second stage filter element positioned downstream of the coalescer filter; (i) the filter element of the second stage comprises a folded medium and has a second surface area upstream.

3. The system according to any of claims 1 and 2, characterized in that it further includes: (a) a housing construction defining an interior and having a gas flow inlet and a gas flow outlet; (i) the coalescer filter of the first stage and the filter element of the second stage • are operably positioned within the interior of the housing.

4. The system according to claim 3, characterized in that it further includes: (a) a liquid collection device oriented to receive liquid collected in the coalescer filter of the first stage.

5. The system according to claim 4, characterized in that it further includes: (a) a liquid drain in fluid flow communication with the liquid collection device to drain the collected liquid from inside the housing construction.

6. The system according to any of the claims 3-5, characterized in that: (a) the filter element of the second stage is placed non-permanently operable inside the housing construction to be removable from, and replaceable in the interior of the accommodation construction.

7. The system according to any of claims 1-6, characterized in that: (a) the filter element of the second stage is a panel filter.

8. The system according to any of claims 3-6, characterized in that: (a) the coalescer filter of the first stage is operably placed non-permanently inside the housing construction to be removable from, and replaceable in the Interior of the housing construction.

9. The system according to any of claims 1-8, characterized in that: (a) the coalescer filter of the first stage is a filter element physically separated from the filter element of the second stage.

10. The system according to any of claims 1-9, characterized in that: (a) the coalescer filter comprises a region of coalescent aerosol medium positioned within the coalescer filter housing having first and second opposite sides; (i) the first side of the coalescer filter housing includes an upstream gas flow inlet opening therein; Y (ii) the second side of the coalescer filter housing includes a gas flow outlet opening therein.

11. The system according to claim 1, characterized in that: (a) the coalescer filter includes an outer periphery having a seal member positioned lengthwise; (i) the seal member for creating a seal with a housing construction, when the coalescer filter is operably placed in the housing construction.

12. The system according to any of claims 2 and 11, characterized in that: (a) the seal member is an O-ring.

13. The system according to any of claims 2 and 11, characterized in that: (a) the seal member comprises a molded polymer compressible foam ring positioned along the outer periphery of the coalescer filter housing and having the region of medium embedded in it.

14. The system according to claim 10, characterized in that: (a) the coalescer filter housing has a circular outer periphery; (i) the gas flow inlet upstream of the coalescer filter is positioned eccentrically in relation to the circular outer periphery; and (ii) the gas flow outlet downstream of the coalescer filter is positioned eccentrically in relation to the circular outer periphery.

The system according to any of claims 10 and 14, characterized in that: (a) the gas flow inlet upstream of the coalescer filter is circular; and (b) the gas flow outlet downstream of the coalescer filter is circular.

16. The system according to any of claims 1-15, characterized in that: - '13 - (a) the filter of the second stage comprises a fiberglass filter medium.

17. The system according to claim 16, characterized in that: (a) the filter of the second stage comprises a fiberglass filter medium at least partially coated with an aliphatic fluorocarbon material.

18. The system according to any of claims 1-17, characterized in that: (a) the filter of the second stage comprises a folded medium having a folding depth of at least 5.1 cm (2 inches).

19. The system according to any of claims 1-18, characterized in that: (a) the coalescer filter of the first stage comprises a fibrous medium having a strength in free state not greater than 1.8%.

20. The system according to any of claims 1-19, characterized in that: (a) the coalescer filter of the first stage comprises a fibrous medium having an average fiber diameter of not more than 25 micrometers.

21. The system in accordance with the claim 20, characterized in that: (a) the coalescer filter of the first stage comprises a fibrous medium having an average fiber diameter within the range of 9-25 micrometers.

22. The system according to any of claims 1-21, characterized in that: (a) the coalescer filter of the first stage comprises polyester fibers.

23. The system according to any of claims 1-22, characterized in that: (a) the coalescer filter of the first stage is configured to have an exposed upstream surface area no greater than about 10% of a surface area of the filter element of the second stage.

24. The system according to claim 23, characterized in that: (a) the coalescer filter of the first stage is configured to have an exposed upstream surface area no greater than about 1.5% of the medium surface area of the filter element of the second stage. stage.

25. The system according to any of claims 1-24, characterized in that: (a) the coalescer filter of the first stage comprises a fibrous, coalescent aerosol medium, having: (i) a current exposed surface area, above 6.5 -12.9 square centimeters (1-2 square inches); and (b) the filter element of the second stage comprises a folded medium having at least 45 folds, and having: (i). a crease depth of at least 6.5 cm (2 inches); (ii) a fold length of at least 17.8 cm (7 inches); (iii) a perimeter area of at least 258 square centimeters (40 square inches); and (iv) a surface area of upstream half of at least 0.9 square meters (10 square feet).

26. The system according to any of claims 1-25, characterized in that: (a) the filter element of the second stage includes a coating on a downstream side of the folded medium; (i) the coating comprises a non-metallic material; (b) the coalescer filter of the first stage includes a first and second screens; (i) the first screen covers an upstream portion of the coalescer filter medium; (ii) the second screen covers a portion downstream of the coalescer filter means; (iii) the first and second screens comprise a non-metallic material; and (c) the coalescer filter of the first stage and the coalescer filter of the second stage each comprise at least 99 *% __ of non-metallic material, by weight.

27. The system according to any of claims 1-26, characterized in that it further includes: (a) a diesel engine system having a leakage ventilation; (i) the coalescer filter of the first stage is placed in gas flow communication with the leakage ventilation of the crankcase to receive the leakage gases from it.

28. The system in accordance with the claim 27, characterized in that it further includes: (a) an air intake system in the engine to admit air to the engine system; (i) the system includes a gas flow device constructed and positioned to direct the flow of gas from the filter element of the second stage to the engine air intake system.

29. The system according to any of claims 27 and 28, characterized in that: (a) the engine comprises a diesel engine of at least 50 horsepower.

30. An aerosol coalescer filter, characterized in that it comprises: (a) a region of the coalescent aerosol medium having a first side and a second opposite side; (i) the region of the aerosol coalescent medium comprises a region of fibrous nonwoven medium having an average fiber diameter of not more than 25 microns; and (ii) the first side of the region * of the medium has a first exposed surface area; and (b) a housing having first and second opposite sides; a housing interior and an outer periphery, external to the interior of the housing; (i) the first side of the housing has a first surface with a gas flow opening therein; (ii) the region of the medium is placed within the interior of the housing with the first side of the medium exposed by the opening of the gas flow in the first side of the housing; (iii) the second side of the housing has a second surface with a gas flow opening therein; (iv) the region of the medium is positioned within the housing with the second side of the medium exposed by the gas flow opening in the second side of the housing; and (v) the housing includes a seal member positioned along the outer periphery.

31. The filter according to claim, characterized in that: (a) the seal member includes an O-ring »

32. The filter according to claim 1, characterized in that: (a) the housing comprises a foamed and molded polymeric material defining the outer periphery of the seal member and having a means disposed thereon.

The filter according to any of claims 30-32, characterized in that: (a) the outer periphery of the housing is circular; and (b) the first and second gas flow openings are positioned eccentrically in the housing.

34. The filter according to claim 33, characterized in that: (a) the first and second gas flow openings are circular.

35. A method to treat the exhaust gases of a diesel engine; the method is characterized in that it comprises the steps of: (a) directing the leakage gases from a diesel engine to an aerosol coalescer filter; (b) removing at least a portion of an aerosol phase from the gases with the coalescer filter as a collected liquid; (c) after the step of removing at least "a portion of the aerosol phase, detecting the gases in a half-folded filter; (d) filtering at least a portion of the particulates of the gases with the half-folded filter; and (e) after the step of removing at least a portion of the collected aerosol phase, directing the collected liquid to a drainage construction.

36. The method according to claim 35, characterized in that it includes: (a) after the step of filtering the particulates, directing the gases to an engine air intake system.

37. The method according to any of claims 35 and 36, characterized in that: (a) the step of directing the leakage gases from a diesel engine to a coalescer filter includes directing the leakage gases from a crankcase of a diesel engine of at least 50 horsepower.

38. A method for repairing a diesel engine leak recovery system having a first coalescer aerosol filter and a half-folded filter; the method is characterized in that it includes the steps of: (a) having access to the interior of a housing construction body; (b) removing at least one of a first half fold filter and a first coalescer aerosol filter located in the body from the body; (c) after the removal step, insert at least one of a replacement coalescer filter and a replacement half-fold filter into the body; and (d) closing the access to the interior of the housing construction body.

39. The method for repairing, in accordance with claim 38, characterized in that: (a) the step of accessing includes removing a cover member from the body; (b) the closing step includes replacing the cover member in the body; (c) the step of accessing includes breaking the seal between the cover member and the first half-fold filter; and (d) the closing step includes forming a seal between the cover member and the first or second half fold filter.

40. The method according to any of claims 38 and 39, characterized in that: (a) the step of removing at least one of a first half fold filter and a first coalescer filter of the body includes removing both the first half folded filter as the first coalescer filter; (b) the step of inserting at least one replacement coalescer filter and a replacement half-fold filter into the body includes inserting both a replacement coalescer filter and a replacement half-fold filter; Y (c) after the stirring step, incinerate the first half-fold filter and the first coalescer filter.

41. A panel filter element, characterized in that it comprises: (a) a panel filter construction having a folded filter means and an outer perimeter; the folded filter means comprises; (i) a glass fiber filter medium coated with an aliphatic fluorocarbon material; (ii) at least 40 folds; each of the folds has a crease depth of at least 5.1 cm (2 inches); and (iii) an area within the outer perimeter of at least 226 cm2 (35 square inches); (b) an outer packing member along the outer perimeter comprising a polymeric material; and (c) a half-placed screen in relation to 10 cover with the folded filter medium.

42. The panel filter element, according to claim 41, characterized in that: (a) the folded filter means has at least 15 45 folds and includes: (i) a fold length of at least 17.8 cm (7) inches); (ii) a perimeter area of at least 258 • cm2 (40 square inches); and 20 (iii) a surface area of upstream half of at least 0.9 cm2 (10 square feet); (b) an outer packing member comprising foamed polyurethane; (c) the media screen comprises a non-metallic material; and (d) "the panel filter element further includes a handle operatively connected thereto.