HIGH FLOW DISC FILTER

1 . A filter device configured to filter a liquid, the filter device comprising:

a drum sized to receive the liquid; and

a plurality of filter panels coupled to the drum to define a plurality of discs, the liquid passing through at least a portion of one of the discs, each filter panel including:

a perimeter frame defining a panel normal flow area; and

a filter media coupled to the perimeter frame.

2 . The filter device of claim 1 , wherein the perimeter frame includes two substantially parallel sides and two sides that extend along lines that are substantially radial with respect to the drum.

3 . The filter device of claim 1 , wherein the filter media includes a cloth material.

4 . The filter device of claim 1 , wherein at least one of the plurality of filter panels includes a filter media including a plurality of pleats and at least one reinforcing member configured to maintain the pleated shape of the filter media.

5 . The filter device of claim 4 , wherein the reinforcing member includes at least one stringer extending across the panel normal flow area, and a plurality of ridge bars extending from the stringer in a direction substantially normal to the stringer.

6 . The filter device of claim 5 , wherein the stringer includes a plurality of saw tooths that engage the pleats.

7 . The filter device of claim 5 , wherein the stringer includes a first side that includes saw tooths and a second side that includes saw tooths, and wherein the pleats are sandwiched between the first side and the second side.

8 . The filter device of claim 5 , wherein the stringer is one of a plurality of stringers, each stringer including saw teeth that engage the pleats.

9 . The filter device of claim 5 , wherein the pleats define a plurality of peaks and valleys, and wherein each of the ridge bars is positioned adjacent one of the peaks and valleys.

10 . The filter device of claim 5 , wherein the perimeter frame, the stringer, and the plurality of ridge bars are integrally formed as a single piece around the filter media.

11 . The filter device of claim 1 , wherein the pleats define a media normal flow area that is measured substantially normal to the pleats and that is substantially greater than the panel normal flow area.

12 . The filter device of claim 1 , wherein each filter panel is configured to pass a liquid flow therethrough, the liquid flow being in excess of 3 gallons per minute per square foot and at a pressure differential across the filter media in excess of 12 inches of water.

13 . A filter panel configured for use in a filter device that filters a liquid, the filter panel comprising:

a perimeter frame defining a panel normal flow area.

14 . The filter panel of claim 13 , wherein the perimeter frame includes two substantially parallel sides and two non-parallel sides.

15 . The filter panel of claim 13 , wherein the filter media includes a plurality of pleats and the panel flow area is measured normal to the pleats.

16 . The filter panel of claim 15 , comprising a pleat reinforcing member extending across the panel normal flow area; and a filter media coupled to the perimeter frame and the pleat reinforcing member, the filter media defining a media normal flow area that is substantially greater than the panel normal flow area.

17 . The filter panel of claim 16 , wherein at least one of the reinforcing members is a stringer that includes a plurality of saw tooths that engage the pleats.

18 . The filter panel of claim 17 , wherein the stringer includes a first side that includes saw tooths and a second side that includes saw tooths, and wherein the pleats are sandwiched between the first side and the second side.

19 . The filter panel of claim 17 , wherein the stringer is one of a plurality of stringers, each stringer including saw teeth that engage the pleats.

20 . The filter panel of claim 16 , wherein the reinforcing members include a ridge bar.

21 . The filter panel of claim 20 , wherein the ridge bar is one of a plurality of ridge bars.

22 . The filter panel of claim 21 , wherein the pleats define a plurality of peaks and valleys, and wherein each of the ridge bars is positioned adjacent one of the peaks and valleys.

23 . The filter panel of claim 16 , wherein the perimeter frame and reinforcing members are integrally formed as a single piece around the filter media.

24 . A filter device configured for use in a filter device that filters a liquid, the filter device comprising:

a perimeter frame defining a panel normal flow area;

a stringer extending across the panel normal flow area;

a ridge bar extending from the stringer in a direction substantially normal to the stringer; and

a filter media including a plurality of pleats, the filter media coupled to the perimeter frame, the stringer, and the ridge bar, the perimeter frame, the stringer, and the ridge bar being integrally-formed as a single component around the filter media.

25 . The filter device of claim 24 , wherein the stringer includes a plurality of saw tooths that engage the pleats.

26 . The filter device of claim 24 , wherein the stringer includes a first side that includes saw tooths and a second side that includes saw tooths, and wherein the pleats are sandwiched between the first side and the second side.

27 . The filter device of claim 24 , wherein the stringer is one of a plurality of stringers, each stringer including saw teeth that engage the pleats.

28 . The filter device of claim 27 , wherein the ridge bar is one of a plurality of ridge bars.

29 . The filter device of claim 28 , wherein the pleats define a plurality of peaks and valleys, and wherein each of the ridge bars is positioned adjacent one of the peaks and valleys.

30 . The filter device of claim 24 , wherein the perimeter frame includes two substantially parallel sides and two non-parallel sides.

31 . A method of making a filter panel configured to filter a fluid, the method comprising:

positioning a filter media in an open mold;

closing the open mold to define a plurality of pleats in the filter media; and

injecting a plastic material into the mold, the plastic material flowing around the pleated filter media to define a perimeter frame having a first side and a second side and a plurality of pleat reinforcing members.

32 . The method of claim 31 , further comprising sandwiching the pleats of the filter media between a plurality of first side saw teeth and a plurality of second side saw teeth defined as part of a portion of the plurality of pleat reinforcing members.

33 . The method of claim 31 , further comprising embedding a portion of one of a peak and a valley defined by the pleats in one of the pleat reinforcing members.

34 . The method of claim 31 , wherein the filter media is substantially planar when positioned in the open mold.

35 . A method of filtering a fluid using a plurality of filter panels arranged in a plurality of discs, the method comprising:

directing a flow of unfiltered fluid between a pair of adjacent discs;

passing the unfiltered fluid through a pleated filter media that at least partially defines each of the panels;

selectively rotating the plurality of discs; and

selectively backwashing the filter panels.

36 . The method of claim 35 , further comprising supporting the pleated filter media with at least one of a ridge bar and a stringer.

37 . The method of claim 35 , wherein the fluid includes water.

38 . The method of claim 35 , further comprising supporting the pleated filter media with a plurality of ridge bars and a plurality of stringers.

39 . The method of claim 35 , further comprising passing a liquid through the pleated filter media at a rate of at least 3 gallons per minute per square foot (122 liters per minute per square meter).

40 . Facilitating the performance of a method by providing equipment adapted to the performance of the method, the method comprising:

directing a flow of unfiltered fluid between a pair of adjacent discs;

passing the unfiltered fluid through a pleated filter media that at least partially defines each of the panels;

selectively rotating the plurality of discs; and

selectively backwashing the filter panels.

41 . The method of claim 40 , further comprising supporting the pleated filter media with at least one of a ridge bar and a stringer.

42 . The method of claim 40 , wherein the fluid includes water.

43 . The method of claim 40 , further comprising supporting the pleated filter media with a plurality of ridge bars and a plurality of stringers.

44 . The method of claim 40 , further comprising passing a liquid through the pleated filter media at a rate of at least 3 gallons per minute per square foot (122 liters per minute per square meter).

45 . A method of installing a filter panel in a disc filter that includes a plurality of filter panels arranged to define a plurality of discs, the method comprising:

providing a pleated filter panel having a perimeter;

positioning a gasket around the perimeter of the pleated filter panel;

inserting a portion of the pleated filter panel in a panel receiving space;

tilting the pleated filter panel; and

sandwiching a portion of the pleated filter panel between a locking device and a filter support structure to support the pleated filter panel in an operating orientation.

46 . The method of claim 45 , wherein the panel receiving space includes a slot.

47 . The method of claim 46 , further comprising the step of defining a seal between the entire perimeter of the pleated filter panel and a panel support structure.

48 . A method of replacing the filter media in a disc filter having a drum and non-pleated filter media coupled to the drum, the method comprising:

removing the non-pleated filter media from the drum;

coupling a plurality of filter supports to the drum; and

inserting a pleated filter panel in each of the filter supports to define a plurality of discs.

49 . The method of claim 48 , further comprising molding at least one of the filter supports from a plastic material.