Filter media packs, methods of making, and ultrasonic cutting or welding

1. A method of forming a pleated filter media pack with a filter media sheet, comprising:

pleating the filter media sheet to provide a plurality of pleat panels; and

welding a plurality of seams into a plurality of adjacent pairs of the pleat panels to form a plurality of pocket pleats, wherein opposed side edges of adjacent pairs of the pleat panels are welded along sealed seams along opposed edges of the filter media sheet to form pleat pockets, such that flow between flow faces cannot pass unfiltered through any surrounding sides of the pleated filter media pack without passing through the filter media, the sealed seams being along the surrounding sides, wherein the welding is conducted between an anvil and a weld tool; and

advancing the filter media sheet to the anvil and the weld tool in an unpleated state and successively folding the filter media sheet into pleats between the anvil and the weld tool to provide said pleating.

2. The method of claim 1 , further comprising:

advancing the filter media sheet along a travel path; and

said pleating comprising creasing the filter media sheet at spaced intervals in order to form the pleat panels with a plurality of pleat tips in the pleated filter media pack by extending the creasing in a direction that extends perpendicularly to the travel path.

3. The method of claim 1 , further comprising after the pleating and welding, overlaying the pocket pleats upon each other to form the pleated filter media pack.

4. The method of claim 1 , wherein the filter media sheet comprises at least 10% polymer fibers by weight to facilitate welding.

5. The method of claim 4 , wherein the polymer fibers comprise at least one of a polypropylene and polyester.

6. The method of claim 1 , wherein said welding comprises ultrasonically welding with an ultrasonic press that forms the pocket pleats therebetween, the ultrasonic press comprising the anvil and the weld tool which is in the form of a sonotrode, with a rib projection being provided along at least one of the anvil and the sonotrode.

7. The method of claim 6 , wherein the rib projection is provided on the anvil and projects toward the sonotrode.

8. The method of claim 6 , wherein the rib projection is provided by a removable tool arranged on a plate of at least one of the anvil and the sonotrode, and further comprising: removing the removable tool and rearranging the removable tool or replacing the removable tool with a second removable tool, and using the rearranged removable tool or the second removable tool for forming different configurations of the filter media pack.

9. The method of claim 6 , further comprising linearly reciprocating the anvil and the sonotrode relative to each other together and apart to ultrasonically weld the seams.

10. The method of claim 9 , further comprising:

carrying the anvil on a first carriage mounted on a first linear slide;

carrying the sonotrode on a second carriage mounted on a second linear slide; and

linearly sliding each of the anvil and sonotrode independently, together and apart along a Z axis, to facilitate the welding of the seams and releasing of the pocket pleats to allow overlaying of the pocket pleats upon each other to form the pleated filter media pack.

11. The method of claim 9 , wherein the linearly reciprocating is in a Z-axis, further comprising moving a location of the rib projection along at least one axis perpendicular to the Z axis during formation of the pleated filter media pack to form the pleated filter media pack in an irregular shape of other than a rectangular cuboid.

12. The method of claim 6 , wherein the rib projection comprises first and second parallel linear projection elements in spaced apart relation; and engaging the first and second opposed side edges of the pocket pleats with the first and second parallel linear projection elements.

13. The method of claim 1 , further comprising: intermittently and successively advancing and stopping the filter media sheet along a travel path, wherein while the filter media sheet is stopped at least one of embossing and creasing is conducted and wherein while the filter media sheet is advancing the filter media sheet a leading portion thereof is being folded along a crease.

14. A method of forming a pleated filter media pack with a filter media sheet, comprising:

pleating the filter media sheet to provide a plurality of pleat panels; and

welding a plurality of seams into a plurality of adjacent pairs of the pleat panels to form a plurality of pocket pleats;

wherein the pleated filter media pack comprises a plurality of upstream pleat tips at an upstream face and a plurality of downstream pleat tips at a downstream face with the pleat panels extending between the upstream pleat tips and the downstream pleat tips, each of the pleat panels extending transversely between first and second opposed side edges of the pleat panels, wherein said welding integrally bonds the first and second opposed side edges at spaced apart locations, and wherein the seams extend along the opposed side edges through a midpoint between the upstream face and the downstream face to prevent unfiltered air from passing through opposed sides of the filter media pack when fluid flow occurs between the upstream face and the downstream face; wherein the welding is conducted between an anvil and a weld tool; and

advancing the filter media sheet to the anvil and the weld tool in an unpleated state and successively folding the filter media sheet into pleats between the anvil and the weld tool to provide said pleating.

15. The method of claim 14 , further comprising bonding together the adjacent pleat panels at locations between the first and second opposed side edges.

16. The method of claim 14 , wherein said welding is conducted on at least one of the upstream pleat tips and the downstream pleat tips at spaced apart locations along at least one of the upstream pleat tips and the downstream pleat tips.

17. A method of forming a pleated filter media pack with a filter media sheet, comprising:

pleating the filter media sheet to provide a plurality of pleat panels; and

welding a plurality of seams into a plurality of adjacent pairs of the pleat panels to form a plurality of pocket pleats;

advancing the filter media sheet along a travel path; and

said pleating comprising creasing the filter media sheet at spaced intervals in order to form the pleat panels with a plurality of pleat tips in the pleated filter media pack by extending the creasing in a direction that extends perpendicularly to the travel path;

said welding being done with a reciprocating press comprising an anvil and a weld tool, and supplying thermal energy between the anvil and the weld tool from a thermal energy device to facilitate the welding,

folding the filter media into the pocket pleats using the anvil and the weld tool during relative reciprocating movement between the anvil and the weld tool to facilitate said pleating; and

advancing the filter media sheet to the anvil and the weld tool in an unpleated state and successively folding the filter media sheet into pleats between the anvil and the weld tool.

18. The method of claim 17 , further comprising scoring the filter media sheet to form creases in the filter media sheet that are utilized by the anvil and the weld tool to facilitate said folding.

19. A method of foil ling a pleated filter media pack with a filter media sheet, comprising:

pleating the filter media sheet to provide a plurality of pleat panels; and

welding a plurality of seams into a plurality of adjacent pairs of the pleat panels to form a plurality of pocket pleats, wherein opposed side edges of adjacent pairs of the pleat panels are welded along sealed seams along opposed edges of the filter media sheet to form pleat pockets, such that flow between flow faces cannot pass unfiltered through any surrounding sides of the pleated filter media pack without passing through the filter media, the sealed seams being along the surrounding sides;

wherein said welding comprises ultrasonically welding with an ultrasonic press that forms the pocket pleats therebetween, the ultrasonic press comprising an anvil and a sonotrode, with a rib projection being provided along at least one of the anvil and the sonotrode;

wherein the rib projection comprises first and second parallel linear projection elements in spaced apart relation; and engaging the first and second opposed side edges of the pocket pleats with the first and second parallel linear projection elements;

further comprising a linear slide assembly on which the first and second parallel linear projection elements are mounted, and

adjusting a spacing between the first and second parallel linear projection elements by moving at least one of the first and second linear projections along the linear slide assembly during the formation of the pleated filter media pack to form the pleated filter media pack in an irregular shape of other than a rectangular cuboid.

20. A method of foil ling a pleated filter media pack with a filter media sheet, comprising:

pleating the filter media sheet to provide a plurality of pleat panels; and

welding a plurality of seams into a plurality of adjacent pairs of the pleat panels to form a plurality of pocket pleats, wherein opposed side edges of adjacent pairs of the pleat panels are welded along sealed seams along opposed edges of the filter media sheet to form pleat pockets, such that flow between flow faces cannot pass unfiltered through any surrounding sides of the pleated filter media pack without passing through the filter media, the sealed seams being along the surrounding sides;

wherein said welding comprises ultrasonically welding with an ultrasonic press that forms the pocket pleats therebetween, the ultrasonic press comprising an anvil and a sonotrode, with a rib projection being provided along at least one of the anvil and the sonotrode; and

further comprising a knife projection provided along at least one of the anvil and the sonotrode, the knife projection being thinner than the rib projection; and cutting through the adjacent pairs of pleat panels with the knife projection.

21. The method of claim 20 , further comprising: wherein the knife projection is proximate at least a portion of the rib projection, wherein the knife projection cuts at least one seam that is ultrasonically welded simultaneously by the rib projection.