Filter element and associated filter media providing fuel water separation using surface embossing

A method of processing filter media, comprising the steps of:

• a. providing a layer of filtration media having a surface with a predetermined roughness;
• and
• b. contacting the surface of the layer of filtration media with a device having a selected roughness, selected from the group consisting of a roller or plate, to impart a greater roughness to a portion of the surface of the layer of filtration media than the predetermined roughness;
• forming structural embossments in the surface of the media layer;
• pleating the layer of filtration media to form a plurality of pleat panels with adjacent pleat panels of the plurality of pleat panels having a fold line formed therebetween;
• wherein a plurality of the structural embossments are elongated such that each of the plurality of the structural embossments has a first end and a second end defining an embossment axis extending between the first end and the second end, the embossment axis extending at a non-parallel and non-perpendicular orientation relative to the fold line;
• wherein a first structural embossment and a second structural embossment of the plurality of structural embossments are formed in a first pleat panel of the plurality of pleat panels, the embossment axis of the first structural embossment extending at a different angle than the embossment axis of the second structural embossment:
• wherein a third structural embossment of the plurality of structural embossments is formed in a second pleat panel of the plurality of pleat panels, the second pleat panel being adjacent to the first pleat panel such that a fold line is formed between the first and second pleat panels, the first end of the third structural embossment being positioned axially between the first ends of the first and second structural embossments along the fold line and the first end of the second structural embossment being positioned axially between the first and second ends of the third structural embossment.

A method of processing filter media, comprising the steps of:

• a. providing a layer of filtration media having a surface with a predetermined roughness;
• and
• b. contacting the surface of the layer of filtration media with a device having a selected roughness, selected from the group consisting of a roller or plate, to impart a greater roughness to a portion of the surface of the media than the predetermined roughness;
• wherein the roller or plate has a surface roughness that is at least 116μ.

A method of processing filter media, comprising the steps of:

• a. providing a layer of filtration media having a surface with a predetermined roughness;
• and
• b. contacting the surface of the layer of filtration media with a device having a selected roughness, selected from the group consisting of a roller or plate, to impart a greater roughness to a portion of the surface of the layer of filtration media than the predetermined roughness;
• wherein the step of contacting the portion of the surface of the layer of the filtration media with a device having a selected roughness to impart a greater roughness to the portion of the surface of the layer of filtration media than the predetermined roughness is performed by compacting the portion of the surface of the layer of filtration media to form the greater roughness.

A method of processing filter media, comprising the steps of:

• a. providing a layer of filtration media having a surface with a predetermined roughness;
• and
• b. contacting the surface of the layer of filtration media with a device having a selected roughness, selected from the group consisting of a roller or plate, to impart a greater roughness to a portion of the surface of the layer of filtration media than the predetermined roughness;
• wherein the step of contacting the surface of the layer of filtration media with a device causes the surface roughness of the portion of the surface of the layer of filtration media to have a contact angle that is measured using a goniometer with water of between 130 degrees and 140 degrees.

A filter element comprising:

• a pleated filter media pack formed from a layer of filtration media, the layer of filtration media forming a plurality of pleat panels formed by a plurality of fold lines, the layer of filtration media having an upstream surface and a downstream surface:
• a portion of the upstream surface being compressed to have a desired surface roughness;
• wherein the layer of filtration media includes structural embossments in the upstream surface of the layer of filtration media;
• wherein a plurality of the structural embossments are elongated such that each of the plurality of the structural embossments has a first end and a second end defining an embossment axis extending between the first end and the second end, the embossment axis extending at a non-parallel and non-perpendicular orientation relative to the fold lines;
• wherein a first structural embossment and a second structural embossment of the plurality of structural embossments are formed in a first pleat panel of the plurality of pleat panels, the embossment axis of the first structural embossment extending at a different angle than the embossment axis of the second structural embossment;
• and
• wherein a third structural embossment of the plurality of structural embossments is formed in a second pleat panel of the plurality of pleat panels, a first fold line of the plurality of fold lines that is formed between the first and second pleat panels, the first end of the third structural embossment being positioned axially between the first ends of the first and second structural embossments along the first fold line and the first end of the second structural embossment being positioned axially between the first and second ends of the third structural embossment.

A filter element comprising:

• a pleated filter media pack formed from a layer of filtration media, the layer of filtration media forming a plurality of pleat panels formed by a plurality of fold lines, the layer of filtration media having an upstream surface and a downstream surface;
• a portion of the upstream surface being compressed to have a desired surface roughness;
• and
• wherein the surface roughness of the portion of the upstream surface is at least 116μ.