Apparatus and methods for forming filter sleeves having circumferential pleats for use in a bag-type filter assembly
Systems are provided for fabricating a plurality of possible pleat packs used in the formation of circumferentially pleated filter sleeves comprising a substantially horizontal contact surface, a pleating machine having cutting structure, operatively positioned proximate the substantially horizontal contact plane, for delivering continuous upstanding pleat packs of a predetermined pleat formation to the horizontal contact surface, structure for guiding the upstanding pleat packs received from the pleating machine into a flattened condition, structure for securing the pleat packs in the flattened condition and structure for forming the flattened pleat packs into a predetermined length for subsequent formation into sleeves of circumferential pleats. Methods for fabricating a plurality of possible pleat packs used in the formation of circumferentially pleated filter sleeves are also provided.
1. A method for fabricating pleat packs used in the formation of circumferentially pleated filter sleeves, the method comprising the acts of:
positioning a pleating machine proximate a substantially horizontal contact surface;
delivering continuous upstanding pleat packs of a predetermined pleat formation from the pleating machine to the horizontal contact surface, the predetermined pleat formation comprising adjoining upstanding pleats each comprising a first pleat leg and a second pleat leg, wherein the first pleat leg of each upstanding pleat does not overlap the second pleat leg of an adjoining upstanding pleat;
guiding the continuous upstanding pleat packs received from the pleating machine into a flattened condition on the substantially horizontal contact surface;
securing the pleat packs in the flattened condition; and
after securing, forming the flattened pleat packs into a predetermined length for subsequent formation into sleeves of circumferential pleats.
2. The method of claim 1 further comprising the act of:
positioning structure proximal the substantially horizontal contact surface, for moving the upstanding pleats from the pleating machine to the substantially horizontal contact surface.
3. The method of claim 1 wherein the substantially horizontal contact surface is a stationary contact surface.
4. The method of claim 1 wherein the substantially horizontal contact surface is a moving contact surface.
5. The method of claim 1 further comprising the act of:
passing the flattened pleat packs between a pair of opposing rollers positioned proximal the substantially horizontal contact surface.
6. The method of claim 5 further comprising the act of:
compressing the flattened pleats in an adjustable compression gap positioned between the pair of opposed rollers.
7. The method of claim 1 wherein the predetermined pleat formation is selected from the group consisting of standard straight pleats, saw tooth pleats, flat bottom pleats, square pleats, symmetric W pleats, and asymmetric W pleats.
8. The method of claim 1 wherein the pleating machine
comprises a CNC machine programmable to deliver continuous upstanding pleat packs of more than one predetermined pleat formation.
9. The method of claim 1 further comprising the act of:
continuously laminating the flattened pleats with at least one laminate;
calendaring the laminated pleats to convert the laminated pleats into an integral composite structure.