阅读说明：本技术 过滤器元件、空气滤清器组件和方法 (Filter element, air cleaner assembly and method ) 是由 M·佛斯特拉 B·卡途尔 W·范诺登霍韦 M·琼克希尔 B·K·尼尔森 D·J·伯顿 S 于 2020-02-07 设计创作，主要内容包括：一种空气滤清器组件,包括壳体和可移除的盖。过滤器元件可移除地定位在所述壳体中。两部分配合的锁扣组件包括紧固到所述盖的第一部分和位于所述壳体和所述过滤器元件之一上的第二部分。当所述过滤器元件可操作地安装在所述壳体内时,所述第一部分和所述第二部分被定位成可释放地配合。(An air cleaner assembly includes a housing and a removable cover. A filter element is removably positioned in the housing. A two-part mating latch assembly includes a first part secured to the cover and a second part on one of the housing and the filter element. The first portion and the second portion are positioned to releasably mate when the filter element is operably mounted within the housing.)

1. An air cleaner assembly comprising:

(a) a housing having an interior volume and an inlet opening in communication with the interior volume;

(b) a cover removably oriented over the inlet opening;

(c) a filter element removably oriented in the interior volume of the housing;

(d) the two parts are matched with each other;

(i) a first portion of the two-part mating latch assembly is secured to the cover;

(ii) a second portion of the two-part mating latch assembly is located on one of the housing and the filter element; and

(iii) the first and second portions of the latch assembly are positioned to releasably mate when the filter element is operably installed within the housing interior volume.

2. The air cleaner assembly of claim 1, wherein the second portion is integral with the housing and is movable radially outward from a remainder of the housing when the filter element is operatively mounted within the housing interior volume.

3. The air cleaner of claim 2, wherein the filter element is constructed and arranged to urge the second portion radially outward from the remainder of the housing when the filter element is operatively mounted within the housing interior volume.

4. The air cleaner of claim 1, wherein the filter element includes a second portion secured thereto; the second portion extends through an opening in the housing when the filter element is operably mounted within the housing interior volume.

5. The air cleaner of claim 4, wherein the filter element includes a frame surrounding the filter media, and an ear formation extending from the frame; the second portion protrudes from the ear configuration.

6. The air cleaner of claim 5, wherein the filter element has a longitudinal axis extending therethrough; and the second portion projects from the ear formation parallel to the longitudinal axis.

7. The air cleaner of claim 6, wherein the filter element includes z-media forming opposing flow faces; the longitudinal axis passes through both flow faces; and the second portion includes a pair of fins positioned laterally spaced from the z-media and projecting in a direction away from the flow face and the z-media.

8. The air cleaner of any one of claims 5-7, wherein the ear configuration includes a pair of ears each extending from the frame.

9. The air cleaner of any one of claims 1-8, wherein the first portion of the two-part latch assembly is a latch and the second portion is a retainer.

10. The air cleaner of claims 1-9, wherein the first portion of the two-part latch assembly is an over-center latch having a lever and a hook, and the second portion is a retainer.

11. The air cleaner of any one of claims 1-4, wherein the filter element includes a frame surrounding a filter media; a longitudinal axis extending therethrough; and an ear formation extending from the frame; the ear configuration includes an arrangement of projections extending therefrom in a direction parallel to the longitudinal axis.

12. The air cleaner of claim 11, wherein the arrangement of projections includes one or more fins.

13. The air cleaner of claim 12, wherein the filter element includes z-media forming opposing flow faces; the longitudinal axis passes through both flow faces; and the one or more fins are positioned laterally spaced from the z-media and project in a direction away from the flow face and the z-media.

14. The air cleaner of claim 13, wherein the flap is positioned such that the flap urges the second portion radially outward from the remainder of the housing when the filter element is operatively mounted within the housing interior volume.

15. The air cleaner of any one of claims 1-14, wherein:

(a) the filter element comprises a media pack comprising filter media and having first and second opposite flow faces;

(i) the first flow end comprises an inlet flow face;

(ii) the second flow end comprises an outlet flow face; and

(iii) the media pack configured to filter air flowing into the inlet flow face before the air exits the outlet flow face;

(b) a frame mounted to the media pack; and

(c) a sealing arrangement positioned on the frame;

(i) the sealing arrangement includes a sealing member oriented to releasably, sealingly engage the housing.

16. The air cleaner of claim 15, wherein the sealing member is radially directed and oriented to form a radial seal with the housing.

17. The air cleaner of any one of claims 15 and 16, wherein:

(a) the filtration media comprises fluted media having inlet flutes and outlet flutes;

(i) the inlet flutes being open at the inlet flow face and blocked downstream of the inlet flow face; and is

(ii) The outlet flutes are open at the outlet flow face and blocked upstream of the outlet flow face.

18. The air cleaner of any one of claims 1-17, wherein the filter element includes an ear formation extending from the frame; the ear configuration has an arrangement of projections extending therefrom.

19. The air cleaner of any one of claims 1-18, wherein the filter element is racetrack-shaped having opposing curved ends joined by straight edges.

20. The air cleaner of any one of claims 1-19, wherein:

(a) the first portion of the two-part mating shackle assembly comprises a latch member;

(b) said second part of said two-part mating latch assembly comprising a radially inwardly deflectable flange having a flange tab with a through hole; and a stationary housing fin having a through hole; and is

(c) The filter element includes a radially extending plug or rib positioned to urge the radially inwardly deflectable flange radially outward until the through-hole of the flange tab is axially aligned with the through-hole of the stationary housing tab to allow the latch member to be received through the aligned through-hole.

21. The air cleaner of any one of claims 1-19, wherein:

(a) the first portion of the two-part mating shackle assembly comprises an eccentric latch member;

(b) the second portion of the two-part mating latch assembly comprises a pivoting member comprising an arm that pivots about a hinge point on the housing; the arm having a finger and a catch; and is

(c) The filter element includes a radially extending plug or rib positioned to push the pivot member downward to rotate the arm from an interference position to a non-interference position and allow the over-center latch to engage with the catch on the finger.

22. A method of installing a filter element in a housing of an air cleaner; the method comprises the following steps:

(a) orienting a filter element into an interior volume of a housing through an inlet opening in the housing;

(b) orienting a cover over the inlet opening; and

(c) releasably mating first and second portions of a two-part mating latch assembly to secure the cover to the housing;

(i) a first part of a two-part mating latch assembly is secured to the cover; and

(ii) a second portion of the two-part mating latch assembly is located on one of the housing and the filter element.

23. The method of claim 22, wherein:

(a) the second portion is integral with the housing; and is

(b) The step of orienting the filter element includes urging the second portion radially outward from a remainder of the housing using the filter element.

24. The method of claim 22, wherein:

(a) the filter element includes a second portion secured thereto; and is

(b) The step of orienting the filter element includes extending the second portion through an opening in the housing when the filter element is operably mounted within the housing interior volume.

25. A filter element for use in a housing of an air cleaner; the element comprises:

(a) a media pack comprising filter media; and

(b) an interference engagement member adapted to interact with an interference member on the housing.

26. A filter element for use in a housing of an air cleaner, the element comprising:

(a) a media pack comprising filter media; and

(b) an interference engagement member sized and adapted to engage and move an interference member to a non-interference position, wherein the interference member prevents the housing from mating with the cover unless the filter element is installed in the housing.

27. A filter element for use in a housing of an air cleaner, the element comprising:

(a) a media pack comprising filter media; and

(b) a projection arrangement sized and adapted to engage a latch assembly integral with the housing of the air cleaner.

28. The filter element of any of claims 25-27, further comprising a frame mounted to the media pack.

29. The filter element of any of claims 25-28, further comprising a sealing arrangement.

30. The filter element of any of claims 25-29, further comprising a frame mounted to the media pack and a sealing arrangement positioned on the frame.

31. The filter element of any one of claims 25-28, further comprising an ear configuration.

32. A filter element according to claim 27 and claim 31, wherein the arrangement of projections extends from the ear formation parallel to a longitudinal axis extending through the element.

33. The filter element of any one of claims 25-32 wherein:

(a) the media pack having first and second opposite flow faces;

(i) the first flow end comprises an inlet flow face;

(ii) the second flow end comprises an outlet flow face; and

(iii) the media pack configured to filter air flowing into the inlet flow face and out through the outlet flow face; and

(b) a longitudinal axis passes through both the inlet flow face and the outlet flow face.

34. The filter element of claims 32 and 33, wherein the arrangement of projections comprises a pair of tabs positioned laterally spaced from the media pack and projecting in a direction away from the flow face.

35. The filter element of claim 31 and any one of claims 32-34, wherein:

(a) the ear arrangement includes a pair of ears each extending laterally from the frame; and is

(b) There is at least one tab extending from each of the ears.

36. The filter element of claim 29 and any one of claims 30-35, wherein the sealing arrangement comprises a sealing member oriented to releasably, sealingly engage the housing.

37. The filter element of claim 36, wherein the sealing member is radially directed and oriented to form a radial seal with the housing.

38. The filter element of claim 37, wherein the sealing member is an outwardly directed radial seal.

39. The filter element of any one of claims 25-38, wherein the filter element is racetrack shaped, having opposing curved ends joined by straight edges.

40. The filter element of claim 33 and any of claims 34-39, further comprising a surface mesh above one of the flow faces.

41. A filter element according to claim 27 and any one of claims 28 to 40, wherein the arrangement of projections extends from the ear formation by at least 10mm and no more than 100 mm.

42. A filter element according to claim 27 and any one of claims 28 to 40, wherein the arrangement of projections extends from the ear formation by at least 15mm and no more than 80 mm.

43. The filter element of any of claims 25-27 and 28-42, wherein the interference engagement members comprise one or more plugs extending radially outward from a sidewall of the filter element.

44. The filter element of any of claims 25-27 and 28-42, wherein the interference engagement member comprises one or more ribs extending radially outward from a sidewall of the filter element.

45. An air cleaner having a housing and a filter element according to any one of claims 25 to 44, wherein the interference member is a movable latch member.

46. An air cleaner having a housing and a filter element according to any one of claims 25 to 44, wherein the interference member is

47. An air cleaner having a housing and a filter element according to any one of claims 25 to 44, wherein the interference member is deformable.

48. An air cleaner having a housing and a filter element according to any one of claims 25 to 44, wherein the interference member is a radially inwardly deflectable flange.

49. An air cleaner having a housing and a filter element according to any one of claims 25 to 44, wherein the interference member is rotatable.

50. An air cleaner having a housing and a filter element according to any one of claims 25 to 44, wherein the interference member is pivotable.

Technical Field

The present disclosure relates to filter arrangements, typically for filtering air; such as the intake air of an internal combustion engine. The present disclosure relates in particular to filter arrangements involving elements (cartridges) having opposite flow ends. Air filter arrangements, components and features are described; and methods of assembly and use.

Background

Contaminant material, such as dust and liquid particles, may be entrained in the air stream. In many cases, it is desirable to filter some or all of the contaminant material out of the air stream. For example, air flow streams (e.g., combustion air streams) to engines for motor vehicles or for power generation equipment, gas streams to gas turbine systems, and air streams to various combustion furnaces carry particulate contaminants therein that should be filtered. It is preferred for such systems to remove (or reduce the content of) selected contaminant materials from the air.

To remove such contaminants, a wide variety of air filter arrangements have been developed. They typically include a main filter element that is serviceable (i.e., removable and replaceable). It is desirable for the main filter element to: easy maintenance, having a configuration that is easily and properly sealed within the air cleaner assembly during use thereof; also, it is preferably configured in combination with the air cleaner assembly such that improper or unauthorized components cannot be easily installed or displayed as installed. Methods to address this problem have been developed; see, e.g., WO 2014/210541 and WO 2016/105560, which are incorporated herein by reference. Improvements are sought.

Disclosure of Invention

In accordance with the present disclosure, air cleaner assemblies, components, features, and related methods are described. The air filter element of the described features may be used as a serviceable filter element in an air cleaner assembly, such as, for example, to filter intake air and an internal combustion engine.

In general, an air cleaner assembly is provided that improves upon the prior art.

In one aspect, an air cleaner is provided, the air cleaner comprising: (a) a housing having an interior volume and an inlet opening in communication with the interior volume; (b) a cover removably oriented over the inlet opening; (c) a filter element removably oriented in the interior volume of the housing; (d) the two parts are matched with each other; (i) a first part of a two-part mating latch assembly is secured to the cover; (ii) a second portion of the two-part mating latch assembly is located on one of the housing and the filter element; and (iii) the first and second portions of the latch assembly are positioned to releasably mate when the filter element is operably installed within the housing interior volume.

In some aspects, the second portion is integral with the housing and is movable radially outward from a remainder of the housing when the filter element is operably mounted within the housing interior volume.

In some aspects, the filter element is constructed and arranged to urge the second portion radially outward from a remainder of the housing when the filter element is operably mounted within the housing interior volume.

In some aspects, the filter element includes a second portion secured thereto; the second portion extends through the opening in the housing when the filter element is operably mounted within the housing interior volume.

In some aspects, a filter element includes a frame surrounding a filter media, and an ear configuration extending from the frame; a second portion projects from the ear configuration.

In some aspects, the filter element has a longitudinal axis extending therethrough; and the second portion projects from the ear formation parallel to the longitudinal axis.

In some aspects, the filter element comprises z-media forming opposing flow faces; the longitudinal axis passes through both flow faces; and the second portion includes a pair of fins positioned laterally spaced from the z-media and projecting in a direction away from the flow face and the z-media.

In some aspects, the ear configuration includes a pair of ears each extending from the frame.

In some aspects, the first portion of the two-part latch assembly is a latch and the second portion is a hook.

In some aspects, the first portion of the two-part latch assembly is an over-center latch and the second portion is a hook.

In some aspects, the filter element comprises a frame surrounding the filter media; a longitudinal axis extending therethrough; and an ear formation extending from the frame; the ear configuration includes an arrangement of projections extending therefrom in a direction parallel to the longitudinal axis.

In some aspects, the projection arrangement comprises one or more tabs.

In some aspects, the filter element comprises z-media forming opposing flow faces; the longitudinal axis passes through both flow faces; and the one or more fins are positioned laterally spaced from the z-media and project in a direction away from the flow face and the z-media.

In some aspects, the tab is positioned such that when the filter element is operably installed within the housing interior volume, the tab pushes the second portion radially outward from the remainder of the housing.

In some aspects: (a) the filter element comprises a media pack comprising filter media and having first and second opposite flow faces; (i) the first flow end includes an inlet flow face; (ii) the second flow end includes an outlet flow face; and (iii) the media pack is configured to filter air flowing into the inlet flow face before the air exits the outlet flow face; (b) a frame mounted to the media pack; and (c) a sealing arrangement positioned on the frame; (i) the sealing arrangement includes a sealing member oriented to releasably, sealingly engage the housing.

In some aspects, the seal member is radially directed and oriented to form a radial seal with the housing.

In some aspects: (a) the filtration media comprises fluted media having inlet flutes and outlet flutes; (i) the inlet flutes being open at the inlet flow face and blocked downstream of the inlet flow face; and (ii) the outlet flutes are open at the outlet flow face and blocked upstream of the outlet flow face.

In some aspects, the filter element includes an ear formation extending from the frame; the ear configuration has an arrangement of projections extending therefrom.

In some aspects, the filter element is racetrack shaped, having opposing curved ends joined by straight edges.

In one or more exemplary embodiments, a first portion of a two-part mating shackle assembly includes a latch member; a second part of the two-part mating latch assembly includes a radially inwardly deflectable flange having a flange tab with a through hole; and a stationary housing fin having a through hole; and the filter element includes a radially extending plug or rib positioned to urge the radially inwardly deflectable flange radially outward until the through-hole of the flange tab is axially aligned with the through-hole of the stationary housing tab to allow the latch member to be received through the aligned through-hole.

In some example embodiments, a first portion of a two-part mating latch assembly includes an over-center latch member; the second part of the two-part mating latch assembly comprises a pivoting member comprising an arm that pivots about a hinge point on the housing; the arm having a finger and a catch; and the filter element includes a radially extending plug or rib positioned to push the pivot member downward to rotate the arm from the interference position to the non-interference position and allow the over-center latch to engage the catch on the finger.

In another aspect, a method of installing a filter element in a housing of an air cleaner is provided. The method comprises the following steps: (a) orienting a filter element into an interior volume of a housing through an inlet opening in the housing; (b) orienting a cover over the inlet opening; and (c) releasably mating the first and second parts of the two-part mating latch assembly to secure the cover to the housing; (i) a first part of a two-part mating latch assembly is secured to the cover; and (ii) a second portion of the two-part mating latch assembly is located on one of the housing and the filter element.

In some aspects: (a) the second portion is integral with the housing; and (b) the step of orienting the filter element includes urging the second portion radially outward from the remainder of the housing using the filter element.

In some aspects: (a) the filter element includes a second portion secured thereto; and (b) orienting the filter element includes extending the second portion through the opening in the housing when the filter element is operably mounted within the housing interior volume.

In yet another aspect, a filter element for use in a housing of an air cleaner is provided; the element comprises a media pack comprising filter media; and an interference engagement member.

In another aspect, a filter element for use in a housing of an air cleaner is provided; the element comprises a media pack comprising filter media; and an interference engagement member sized and adapted to engage and move the interference member to a non-interference position, wherein the interference member prevents the housing from mating with the cover unless the filter element is installed in the housing.

In another aspect, a filter element for use in a housing of an air cleaner is provided; the element comprises a media pack comprising filter media; and a projection arrangement sized and adapted to engage a latch assembly integral with a housing of the air cleaner.

The element may comprise a frame mounted to the media pack.

The element may further comprise a sealing arrangement.

The element may further comprise a frame mounted to the media pack and a sealing arrangement positioned on the frame.

The element may comprise an ear configuration.

The projection arrangement may extend from the ear formation parallel to a longitudinal axis extending through the element.

The media pack may have first and second opposite flow faces; the first flow end includes an inlet flow face; the second flow end includes an outlet flow face; and the media pack is configured to filter air flowing into the inlet flow face and out through the outlet flow face.

The longitudinal axis passes through both the inlet flow face and the outlet flow face.

The projection arrangement may include a pair of tabs located laterally spaced from the media pack and projecting in a direction away from the flow face.

The ear configuration may include a pair of ears each extending laterally from the frame; and there is at least one tab extending from each ear.

The sealing arrangement may comprise a sealing member oriented to releasably, sealingly engage the housing.

The sealing member may be radially directed and oriented to form a radial seal with the housing.

The sealing member may be an outwardly directed radial seal.

The filter element may be racetrack shaped with opposing curved ends joined by straight edges.

The filter element may further comprise a surface mesh over one of the flow faces.

The projection arrangement may extend at least 10mm and no more than 100mm from the ear configuration.

The projection arrangement may extend at least 15mm and no more than 80mm from the ear configuration.

In some example embodiments, the interference engagement members include one or more plugs extending radially outward from a sidewall of the filter element.

In some example embodiments, the interference engagement members include one or more ribs extending radially outward from the sidewall of the filter element.

It should be noted that not all of the specific features described herein need be incorporated into an arrangement to provide the arrangement with some selected advantage in accordance with the present disclosure.

Drawings

FIG. 1 is a partial schematic perspective view of a single facer strip of z-shaped filtration media comprising a fluted sheet secured to a facing sheet;

FIG. 2 is an enlarged schematic partial view of a single facer sheet comprising fluted media secured to facing media;

FIG. 3 is a schematic representation of various selected flute shapes;

figure 3A is a schematic partial cross-sectional view of another fluted media configuration in a single facer media pack;

figure 3B is a schematic partial cross-sectional view of yet another alternative flute definition;

figure 3C is a schematic partial cross-sectional view of another flute definition of the media pack;

FIG. 4 is a schematic illustration of a process for making a single facer media for use in a media pack according to the present disclosure;

figure 5 is a schematic cross-sectional view of an example of an embossed flute;

FIG. 6 is a schematic perspective view of a wound media construction comprising a wound sheet of single facer media material;

FIG. 7 is a schematic perspective view of a stacked media configuration;

fig. 8 is a schematic flow end view of a filter media pack that uses an alternative to the media of fig. 1 and that may alternatively be used in selected filter cartridges according to the present disclosure.

Fig. 9 is a schematic flow end view opposite the view of fig. 8.

FIG. 10 is a schematic cross-sectional view of the media pack of FIGS. 8 and 9;

fig. 11 is a schematic partial cross-sectional view of yet another alternative media type that may be used in a media pack of a filter cartridge having features according to the present disclosure.

Fig. 12 is a schematic partial cross-sectional view of a first variation of the media type of fig. 11.

Figure 13 is a schematic partial depiction of another useful fluted sheet/facing sheet combination according to the present disclosure.

FIG. 14 is a second schematic illustration of a portion of the media type of FIG. 13 shown in a media pack.

FIG. 15 is a schematic partial plan view of yet another media variation that may be used in an arrangement according to the present disclosure.

FIG. 16 is a schematic view of another variation of a usable medium according to the present disclosure.

Figure 17 is a schematic depiction of another useful fluted sheet/facing sheet combination according to the present disclosure.

Figure 18 is a perspective view of a portion of a useful fluted sheet/facing sheet combination depicted in figure 17.

FIG. 19 is a perspective view of another media variation that may be used in an arrangement according to the present disclosure;

FIG. 20 is a schematic perspective view of a portion of a support section of the filter media of FIG. 19 shown in a folded configuration but unfolded or separated for illustration purposes;

FIG. 21 is a schematic cross-sectional view of a portion of the support section of the filter media of FIG. 19 shown in a folded configuration but unfolded or separated for illustration purposes;

FIG. 22 is a perspective view of another media variation that may be used in an arrangement according to the present disclosure.

FIG. 23 is a perspective view of a first embodiment of an air cleaner assembly constructed in accordance with the principles of the present disclosure;

FIG. 24 is a perspective view of an enlarged area of the air cleaner assembly shown at "A" in FIG. 23;

FIG. 25 is a perspective view of an embodiment of a filter element that may be used in the air cleaner assembly of FIG. 23;

FIG. 26 is a perspective view showing the filter element of FIG. 25 during a step of installation in the air cleaner assembly of FIG. 23;

FIG. 27 is a perspective view of a portion of the assembly of the air cleaner housing of FIG. 23 and a portion of the filter element of FIG. 25;

FIG. 28 is an enlarged cross-sectional view of a portion of the filter element installed in the air cleaner housing of FIG. 23;

FIG. 29 is an enlarged perspective view of a portion of the air cleaner assembly of FIG. 23 with the filter element of FIG. 25 installed therein;

FIG. 30 is a perspective view of a second embodiment of a housing of an air cleaner assembly, depicted without a filter element installed therein and without a cover member;

FIG. 31 is an enlarged view of region "B" of FIG. 30;

FIG. 32 is a perspective view of a portion of a filter element that may be used with the air cleaner assembly of FIG. 30, the filter element shown with the frame and shown prior to the sealing arrangement being in place;

FIG. 33 is a perspective view of a portion of an air cleaner assembly during a step of installing a filter element therein;

FIG. 34 is a perspective view similar to FIG. 33 and showing a filter element operatively mounted within the air cleaner housing; and is

FIG. 35 is a perspective view of an air cleaner assembly with a filter element installed therein and a cover member locked in place on the air cleaner housing.

FIG. 36 is a perspective view of another embodiment of an air cleaner assembly during an installation step of the element;

FIG. 37 is a perspective view of the air cleaner assembly of FIG. 36 during yet another installation step of the component;

FIG. 38 is a schematic cross-sectional view of the housing and components of FIG. 36 during one assembly step;

FIG. 39 is a schematic cross-sectional view of the housing and components of FIG. 36 during one assembly step;

FIG. 40 is a schematic cross-sectional view of the cover and housing and components of FIG. 36 in final assembly;

FIG. 41 is a perspective view of another embodiment of an air cleaner assembly during an installation step of the element;

FIG. 42 is a perspective view of the air cleaner assembly of FIG. 41 during yet another installation step of the element;

FIG. 43 is a schematic cross-sectional view of another embodiment;

FIG. 44 is a perspective view of another embodiment of an air cleaner assembly during an installation step of the element;

FIG. 45 is a perspective view of the air cleaner assembly of FIG. 44 during yet another installation step of the component;

FIG. 46 is a perspective view of the air cleaner assembly of FIG. 44 during yet another installation step of the component;

FIG. 47 is a perspective view of the air cleaner assembly of FIG. 44 during yet another installation step of the component;

FIG. 48 is a schematic cross-sectional view of the housing and components of FIG. 44 during one assembly step;

FIG. 49 is a schematic cross-sectional view of the cover and housing and components of FIG. 44 in final assembly;

FIG. 50 is a perspective view of another embodiment of an air cleaner assembly during an installation step of the element;

FIG. 51 is a perspective view of the air cleaner assembly of FIG. 50 during yet another installation step of the element;

FIG. 52 is a perspective view of the air cleaner assembly of FIG. 50 during yet another installation step of the component;

FIG. 53 is a schematic cross-sectional view of the housing and components of FIG. 50 during one assembly step;

FIG. 54 is a schematic cross-sectional view of the housing and components of FIG. 50 during one assembly step;

FIG. 55 is a schematic cross-sectional view of the cover and housing and components of FIG. 50 in final assembly;

FIG. 56 is a perspective view of another embodiment of an air cleaner assembly during an installation step of the element;

FIG. 57 is a perspective view of the air cleaner assembly of FIG. 56 during yet another installation step of the component;

FIG. 58 is a perspective view of the air cleaner assembly of FIG. 56 during yet another installation step of the component;

FIG. 59 is a schematic cross-sectional view of another embodiment;

FIG. 60 is a schematic cross-sectional view of another embodiment;

FIG. 61 is a perspective view of another embodiment of an air cleaner assembly during an installation step of the element;

FIG. 62 is a perspective view of the air cleaner assembly of FIG. 61 during yet another installation step of the component;

FIG. 63 is a perspective view of the air cleaner assembly of FIG. 61 during yet another installation step of the element;

FIG. 64 is a schematic cross-sectional view of the housing and components of FIG. 61 during one assembly step;

FIG. 65 is a schematic cross-sectional view of the housing and components of FIG. 61 during one assembly step; and

fig. 66 is a schematic cross-sectional view of the cover and housing and components of fig. 61 in final assembly.

Detailed Description

An overview of the I.Z filter media configuration.

Fluted filtration media can be used to provide a fluid filter construction in a variety of ways. One well known approach is the z-filter configuration. As used herein, the term "z-shaped filter construction" refers to a filter construction that: wherein individual ones of the corrugated, pleated, or otherwise formed filter flutes are used to define sets of longitudinal filter flutes for fluid flow through the media; fluid flows along the length of the flutes between opposite inlet and outlet flow ends (or flow faces) of the media. Some examples of z-shaped filter media are provided in the following documents: us patent 5,820,646; 5,772,883, respectively; 5,902,364, respectively; 5,792,247, respectively; 5,895,574, respectively; 6,210,469, respectively; 6,190,432; 6,350,296, respectively; 6,179,890, respectively; 6,235,195, respectively; des.399,944; des.428,128; des.396,098; des.398,046; and des.437,401; each of these fifteen cited references is incorporated herein by reference.

One type of z-filter media utilizes two particular media components that are joined together to form a media construction. The two components are: (1) a fluted (typically corrugated) media sheet; and (2) a surface media sheet. The facing media sheet is typically non-corrugated, however it may be corrugated, for example perpendicular to the flute direction, as described in U.S. provisional application 60/543,804 filed on 2/11/2004, which is incorporated herein by reference.

A fluted (typically corrugated) media sheet and a facing media sheet together serve to define media having parallel inlet flutes and outlet flutes; that is, the opposite sides of the fluted sheet can operate as an inlet flow region and an outlet flow region. In some examples, the fluted sheet and the non-fluted sheet are secured together and then wound to form a z-shaped filter media construction. Such arrangements are described, for example, in U.S. Pat. nos. 6,235,195 and 6,179,890, each of which is incorporated herein by reference. In certain other arrangements, some non-coiled sections of fluted media secured to flat media are stacked on top of one another to form a filter construction. An example of this is shown in fig. 7 and described in fig. 11 at 5,820,646, which is incorporated herein by reference.

Typically, the facing sheet is wrapped outwardly around itself with the fluted sheet/facing sheet combination to form a rolled media pack. Some techniques for winding are described in U.S. provisional application 60/467,521 filed on 5/2/2003 and PCT application US 04/07927 filed on 3/17/2004 and published on 9/082795/2004 as WO2004/082795, which are incorporated herein by reference. Thus, the resulting coiled arrangement typically has a portion of the facing sheet as the outer surface of the media pack. In some examples, a protective coating may be provided around the media pack.

The term "corrugated" as used herein to refer to media construction refers to a fluted construction resulting from passing media between two corrugating rolls, i.e., into a nip or roll gap between the two rolls, each of which has appropriate surface features to cause a corrugation effect in the resulting media. The term "corrugation" does not refer to flutes formed by not involving the passage of media through the nip between the corrugation rolls. However, the term "corrugated" is intended to apply even if the media is further modified or deformed after being corrugated, for example, by the folding technique described in PCT WO 04/007054 published 1/22 of 2004, which is incorporated herein by reference.

Corrugated media is a special form of fluted media. Fluted media is media having individual flutes extending therefrom (e.g., formed by corrugating or folding).

Serviceable filter element or filter cartridge configurations utilizing z-shaped filter media are sometimes referred to as "straight-through flow configurations" or variations thereof. Generally speaking, in this context means that the serviceable filter element generally has an inlet flow end (or face) and an opposite outlet flow end (or face), wherein flow into and out of the filter cartridge is in substantially the same straight-through direction. (the term "straight-through flow configuration" does not take into account, by definition, any air flow out of the media pack through the outermost wrap of face media.) the term "serviceable" is intended in this context to refer to media containing filter cartridges that are periodically removed and replaced from a corresponding air cleaner. In some examples, each of the inlet flow end and the outlet flow end will be substantially flat or planar, and the two are parallel to each other. However, variations of this case (e.g., non-planar faces) are possible.

Generally, the media pack includes suitable sealing material therein to ensure that no unfiltered air flows through the media pack, the sealing material extending completely across and outwardly from the front flow face (inlet flow face) and through the opposite oval face (outlet flow face).

Straight through flow configurations (particularly for coiled media packs) are contrasted, for example, with serviceable filter cartridges, such as cylindrical pleated filter cartridges of the type shown in U.S. Pat. No. 6,039,778, which is incorporated herein by reference, in which the flow is generally diverted as it passes through the serviceable cartridge. That is, in the 6,039,778 filter, the flow enters the cylindrical filter cartridge through the cylindrical side and then turns to exit through the end face (in a forward flow system). In a typical reverse flow system, flow enters a serviceable cylindrical filter element through an end face and then turns to exit through the side of the cylindrical filter element. An example of such a reverse flow system is shown in U.S. patent No. 5,613,992, which is incorporated herein by reference.

The term "z-filter media construction" and variations thereof as used herein is intended to refer only to any or all of the following: a web of corrugated or otherwise fluted media secured to (surface) media by a suitable seal to prevent air from flowing from one flow face to the other without being filtered through the filter media; and/or such media rolled or otherwise configured or formed into a three-dimensional network of flutes; and/or filter constructions comprising such media. In many arrangements, the z-filter media construction is configured to form a network of inlet flutes and outlet flutes, the inlet flutes being open at a region adjacent the inlet face and closed at a region adjacent the outlet face; and, the outlet flutes are closed adjacent the inlet face and open adjacent the outlet face. However, alternative z-shaped filter media arrangements are possible, see, for example, US 2006/0091084 a1, published 5/4/2006, which is incorporated herein by reference; also included are flutes extending between the opposite flow faces with a sealing arrangement to prevent unfiltered air from flowing through the media pack.

In fig. 1 herein, an example of a media 1 that can be used in a z-filter media is shown. The media 1 is formed of a fluted (corrugated) sheet 3 and a facing sheet 4. In this context, a media strip comprising a fluted sheet secured to a facing sheet will sometimes be referred to as a single facer strip, or similar term.

Generally, the corrugated sheet 3 (fig. 1) is of the type generally characterized herein as having a regular, curved, wave-shaped pattern of flutes or corrugations 7. The term "wave pattern" is intended in this context to mean a fluted or corrugated pattern having alternating valleys 7b and ridges 7 a. The term "regular" is intended in this context to refer to the fact that: the pairs of valleys (7b) and ridges (7a) alternate in substantially the same repeating corrugation (or flute) shape and size. (again, typically in a regular configuration, each valley 7b is substantially an inverse of each ridge 7 a.) thus, the term "regular" is intended to indicate that the corrugation (or flute) pattern includes valleys and ridges, with each pair (including adjacent valleys and ridges) repeating, without substantial modification of the size and shape of the corrugation along at least 70% of the flute length. The term "substantial" in this context refers to modifications resulting from changes in the process or form used to create the corrugated or fluted sheet, other than minor changes resulting from the fact that the media sheet 3 is flexible. With respect to the characterization of repeating patterns, it is not meant in any given filter configuration; there must be an equal number of ridges and valleys. The medium 1 may for example terminate between or partly along the pair comprising ridges and valleys. (e.g., in fig. 1, the partially depicted media 1 has eight complete ridges 7a and seven complete valleys 7 b.) furthermore, the opposite flute ends (valley and ridge ends) may be different from each other. Such variations in the ends are negligible in these definitions, unless explicitly stated otherwise. That is, the above definitions are intended to cover variations in flute ends.

In the context of a "curved" wave pattern characterizing a corrugation, the term "curved" is intended to refer to the following corrugation pattern: it is not the result of providing a folded or creased shape for the medium, but rather is formed by the apex 7a of each ridge and the base 7b of each valley along a radiused curve. Although alternatives are possible, a typical radius for such z-shaped filter media will be at least 0.25mm, and typically will be no greater than 3 mm. (non-curved media may also be used, according to the above definition.)

An additional characteristic of the particular regular, curved wave pattern depicted in figure 1 for the corrugated sheet 3 is that a transition region, in which the curvature is reversed, is located approximately at the midpoint 30 between each valley and each adjacent ridge, along a majority of the length of the flute 7. For example, looking at the back side or face 3a (fig. 1), the valleys 7b are concave areas and the ridges 7a are convex areas. Of course, the valleys 7b of the side 3a form ridges when viewed from the front side or face 3 b; and the ridges 7a of the face 3a form valleys. (in some instances, the region 30 may be a straight segment rather than a point, with the curvature reversed at the ends of the segment 30.)

The particular regular, curved, wave-shaped pattern of corrugated sheet material 3 shown in fig. 1 is characterized by individual corrugations being substantially straight. By "straight" in this context is meant that the cross-section of the ridges 7a and valleys 7b does not substantially change throughout at least 70% (typically at least 80%) of the length between the edges 8 and 9. The term "straight" in relation to the corrugated pattern shown in fig. 1 distinguishes the pattern in part from the tapered flutes of corrugated media described in PCT publication WO 03/47722, published 6/12/2003 in fig. 1 of WO 97/40918, which is incorporated herein by reference. The tapered flutes of fig. 1 of WO 97/40918, for example, would be a curved wave pattern, but not a "regular" pattern or a straight flute pattern, as that term is used herein.

Referring to fig. 1 of the present invention and as described above, the medium 1 has a first edge 8 and an opposite second edge 9. When the media 1 is rolled and formed into a media pack, generally, edge 9 will form the inlet end of the media pack and edge 8 the outlet end, although the opposite orientation is possible.

In the example shown, a sealant (in this example, in the form of a sealant bead 10) is provided adjacent the edge 8, sealing the corrugated (fluted) sheet 3 and the facing sheet 4 together. The bead 10 will sometimes be referred to as a "single facer" bead because it is a bead between the corrugated sheet 3 and the facing sheet 4, which bead forms a single facer or media strip 1. A sealant bead 10 seals closed individual flutes 11 adjacent the edge 8 to allow air to pass therethrough.

In the example shown, a sealant (in this example, in the form of a sealing bead 14) is provided adjacent the edge 9. Adjacent to the edge 9, the sealing bead 14 generally closes the flutes 15 to allow unfiltered fluid to pass in the flutes. When the media 1 is wound around itself, the beads 14 will typically be applied with the corrugated sheet 3 directed inwards. Thus, the beads 14 will form a seal between the backside 17 of the surface sheet 4 and the side 18 of the corrugated sheet 3. The bead 14 will sometimes be referred to as a "wrap bead" because it is typically applied with the strip 1 wound into a rolled media pack. If the media 1 is cut into strips and stacked (instead of wound), the beads 14 will be "stacked beads".

Referring to fig. 1, once the media 1 is combined into a media pack, such as by winding or stacking, it may operate as follows. First, air in the direction of arrow 12 will enter open flutes 11 adjacent end 9. Due to the closure by the beads 10 at the end 8, air will pass through the medium, indicated by arrows 13. The air can then exit the media pack by passing through the open ends 15a of the flutes 15 adjacent the end 8 of the media pack. Of course, operation can be performed with the air flow in the opposite direction.

More generally, z-filter media includes fluted filter media secured to facing filter media and configured in a fluted media pack extending between a first flow face and an opposite second flow face. A sealant arrangement is provided within the media pack to ensure that air entering the flutes at the first upstream edge cannot exit the media pack from the downstream edge without being filtered through the media.

For the particular arrangement shown in fig. 1 herein, the parallel corrugations 7a, 7b are substantially completely straight across the media from edge 8 to edge 9. Straight flutes or corrugations may be deformed or folded at selected locations, particularly at the ends. In the above definitions of "regular", "curved" and "wave pattern", the modifications made at the ends of the grooves for closing are generally ignored.

Z-shaped filter constructions that do not utilize a straight, regular, curved wave pattern of corrugation (flute) shapes are known. A corrugated pattern utilizing slightly semi-circular (cross-sectional) inlet flutes adjacent to narrow V-shaped (with curved sides) outlet flutes is shown, for example, in U.S.5,562,825 to Yamada et al (see fig. 1 and 3 of 5,562,825). Circular (in cross-section) or tubular flutes defined by one sheet with half tubes attached to another sheet with half tubes are shown in U.S.5,049,326 to Matsumoto et al, with flat areas between the resulting parallel, straight flutes, see fig. 2 of Matsumoto' 326. Flutes folded to have a rectangular cross section are shown in U.S.4,925,561 (fig. 1) of stone well (Ishii) et al, wherein the flutes are tapered along their length. In WO 97/40918 (fig. 1), flutes or parallel corrugations are shown having a curved wave pattern (convex and concave valleys from adjacent curves) but tapering (and thus not straight) along their length. Further, in WO 97/40918 flutes are shown having a curved wave pattern but with different sizes of ridges and valleys.

In general, filter media is a relatively flexible material, typically a non-woven fibrous material (of cellulosic fibers, synthetic fibers, or both), often including a resin, sometimes treated with additional materials. Thus, it can be conformed or configured into different corrugated patterns without unacceptable media damage. Furthermore, it can be easily wound or otherwise configured for use without also unacceptable media damage. Of course, it must have the properties: so that it will maintain the desired corrugated configuration during use.

During corrugation, the media is inelastically deformed. This prevents the media from returning to its original shape. However, once the tension is released, the flutes or corrugations will tend to spring back, recovering only a portion of the stretching and bending that has occurred. The facing sheet is sometimes bonded to the fluted sheet to prevent such rebound of the corrugated sheet.

Further, typically, the medium comprises a resin. During the corrugation forming process, the media may be heated above the glass transition temperature of the resin. When the resin is subsequently cooled, it will help maintain the fluted shape.

Media having corrugated sheets 3, facing sheets 4 or both may be provided with fine fiber material on one or both sides thereof, for example according to U.S.6,673,136, which is incorporated herein by reference.

A problem with z-filter constructions involves closing the ends of individual flutes. Typically, a sealant or adhesive is provided to effect closure. As is apparent from the above discussion, in typical z-shaped filter media, particularly filter media using straight flutes, a greater sealant surface area (and volume) is required at both the upstream and downstream ends, as opposed to filter media using tapered flutes. High quality sealing at these locations is critical to proper operation of the formed media structure. The large volume and area of encapsulant creates problems associated therewith.

Still referring to fig. 1, at 20, an adhesive bead is shown positioned between the corrugated sheet 3 and the face sheet 4 to secure the two together. The adhesive beads may be, for example, discontinuous lines of adhesive. The sticky beads may also be the points where the media sheets are welded together.

As is evident from the above, the corrugated sheet 3 is typically not continuously fastened to the facing sheet along the valleys or ridges where both abut. Thus, air can flow between adjacent inlet flutes, and alternatively between adjacent outlet flutes, without having to pass through the media. However, air that has entered the inlet flutes cannot exit the outlet flutes without passing through at least one of the media sheets and filtering.

Attention is now directed to fig. 2, which depicts a z-filter media construction 40 utilizing a fluted (in this example, regular, curved, wave pattern corrugated) sheet 43 and a non-corrugated flat, faced sheet 44. The distance D1 between points 50 and 51 defines the extent of the flat media 44 in the region 52 below a given corrugated flute 53. The length D2 of the arcuate media of the corrugated flutes 53 over the same distance D1 is of course greater than D1 due to the shape of the corrugated flutes 53. For typical regularly shaped media used in fluted filter applications, the linear length D2 of the media 53 between points 50 and 51 will typically be at least 1.2 times the D1. Typically, D2 will be in the range of 1.2 to 2.0 times, inclusive. One particularly convenient arrangement of air filters has a configuration in which D2 is about 1.25 to 1.35 x D1. For example, such media have been used commercially in Donaldson Powercore^TMIn a Z-filter arrangement. Herein, the ratio D2/D1 will sometimes be characterized as the flute/flat ratio of the corrugated media or the degree of media stretch.

In the corrugated board industry, different standards of fluting have been defined. For example, standard E flutes, standard X flutes, standard B flutes, standard C flutes, and standard a flutes. Figure 3 provides a definition of these flutes in conjunction with table a below.

The assignee of the present disclosure, Doninson Corporation (DCI), has used variations of standard a and standard B flutes in a variety of z-filter arrangements. These flutes are also defined in table a and fig. 3.

Of course, other standard flute definitions from the corrugated box industry are also known.

In general, standard flute configurations from the corrugated box industry can be used to define the corrugated shape or near-corrugated shape of the corrugated media. The above comparisons between DCI a flute and DCI B flute and corrugated industry standard a flute and standard B flute indicate some convenient variations.

It should be noted that alternative flute definitions may be used, such as the definitions characterized in the following documents: USSN 12/215,718 filed on 26 d 6/2008; and 12/012,785 filed on 4/2/2008 having air cleaner characteristics as characterized hereinafter. The complete disclosure of each of USSN 12/215,718 and 12/012,785 is incorporated herein by reference.

In fig. 3A-3C, cross-sectional views of exemplary portions of filter media are shown in which a fluted sheet has one or more non-peak ridges extending along at least a portion of the flute length. Figure 3A shows a fluted sheet having one non-peaked ridge 81 disposed between adjacent peaks 82, 83, and figures 3B and 3C show fluted sheets having two non-peaked ridges 84, 85 between adjacent peaks 86, 87. The non-peaked ridges 81, 84, 85 can extend along the flute length by any amount, including for example, an amount from 20% of the flute length to 100% of the flute length. Further, a fluted sheet may be provided that has no non-peak ridges 81, 84, 85 between all adjacent peaks 82, 83, 86, 87, and fluted sheets having different numbers of non-peak ridges 81, 84, 85 (e.g., zero, one, or two non-peak ridges alternating in any arrangement) between adjacent peaks 82, 83, 86, 87 may be provided. The presence of the non-peak ridges 81, 84, 85 may help provide more media available for filtration within a given volume and may help reduce stress on the fluted sheet, allowing for a smaller radius at the peak and thus reduced media masking. Such media may be used in an arrangement according to the present disclosure.

Overview of making coiled media configurations using fluted media.

In fig. 4, one example of a manufacturing process for making a media strip (single facer) corresponding to strip 1 (fig. 1) is shown. Generally, the facing sheet 64 and a fluted (corrugated) sheet 66 having flutes 68 are brought together to form a media web 69 with an adhesive bead positioned therebetween at 70. The adhesive bead 70 will form a single-sided layer bead 14 (fig. 1).

The term "single facer bead" refers to a bead of sealant positioned between layers of a single facer; i.e., between the fluted sheet and the facing sheet.

An optional debossing (darting) process occurs at the platform 71 to form a central debossed section 72 located in the middle of the web. The Z-filter media or Z-media strip 74 may be cut or torn at 75 along the bead 70 to form two segments 76, 77 of Z-filter media 74, each of which has an edge with a strip of sealant (single facer bead) extending between the corrugated sheet and the face sheet. Of course, if an alternative staking process is used, the edge with the sealant strip (single facer bead) will also have a set of flutes staked at this location. The strips or segments 76, 77 may then be cut into single facer strips for stacking, as described below in connection with fig. 7.

Techniques for performing the process as characterized with respect to fig. 4 are described in PCT WO 04/007054 published on month 1 and 22 of 2004, which is incorporated herein by reference.

Still referring to fig. 4, the z-shaped filter media 74 must first be formed, then passed over the indenting platform 71 and finally torn at 75. In the schematic shown in fig. 4, this is accomplished by passing the media sheet 92 through a pair of corrugation rollers 94, 95. In the schematic shown in fig. 4, the media sheet 92 is unwound from a roll 96, wound around a tension roll 98, and then passed through a nip or roll gap 102 between the corrugation rolls 94, 95. The corrugation rollers 94, 95 have teeth 104 that will produce corrugations of a generally desired shape after the flat sheet 92 passes through the nip 102. After passing through the nip 102, the sheet 92 becomes cross-machine direction corrugated and is referred to as a corrugated sheet as indicated at 66. The corrugated sheet 66 is then secured to the facing sheet 64. (in some instances, the corrugation forming process may involve heating the media.)

Still referring to fig. 4, the process also shows the facing sheet 64 being transported to an indenting station 71. The face sheet 64 is depicted as being stored on a roller 106 and then directed to the corrugated sheet 66 to form the Z-media 74. The corrugated sheet 66 and the facing sheet 64 will typically be secured together by adhesive or other means, such as by sonic welding.

Referring to fig. 4, an adhesive line 70 is shown for securing the corrugated sheet 66 and the face sheet 64 together as a bead of sealant. Alternatively, the sealant bead used to form the surface bead may be applied as shown at 70 a. If sealant is applied at 70a, it may be desirable to leave a gap in the corrugation roller 95, and it may be possible to leave a gap in both corrugation rollers 94, 95 to accommodate the bead 70 a.

Of course, the apparatus of fig. 4 may be modified to provide for sticky beads 20, if desired.

The type of corrugation provided to the corrugated media is a matter of choice and will be dictated by the corrugation or corrugation teeth of the corrugation rollers 94, 95. One useful corrugation pattern would be a regular curved wave pattern corrugation of straight flutes, as defined herein above. A typical regular curved wave pattern used would be one such pattern: wherein the distance D2 as defined above in the corrugated pattern is at least 1.2 times the distance D1 as defined above. In an example application, typically D2 ═ 1.25 to 1.35 × D1, but alternatives are possible. In some cases, these techniques may be applied to curved wave patterns that are not "regular," including, for example, wave patterns that do not use straight flutes. Further, variations of the curved wave pattern shown are possible.

As described, the process shown in fig. 4 may be used to form the central debossed section 72. Figure 5 shows in cross-section one of the flutes 68 after indenting and tearing.

It can be seen that the folding arrangement 118 forms a indenting flute pattern 120 having four creases 121a, 121b, 121c, 121 d. The folding arrangement 118 includes a flat first layer or portion 122 secured to the face sheet 64. The second layer or portion 124 is shown pressed against the first layer or portion 122. The second layer or portion 124 is preferably formed by folding opposite the outer ends 126, 127 of the first layer or portion 122.

Still referring to fig. 5, two of the folds or creases 121a, 121b will generally be referred to herein as "upper inwardly directed" folds or creases. The term "upper" in this context is intended to indicate: when the fold 120 is viewed in the orientation of fig. 5, the fold is located over the entire upper portion of the fold 120. The term "inwardly directed" is intended to refer to the fact that: the fold or crease line of each fold 121a, 121b is directed toward the other.

In fig. 5, creases 121c, 121d will be generally referred to herein as "lower outwardly directed" creases. The term "lower" in this context refers to the fact that: in the orientation of FIG. 5, creases 121c, 121d are not on top as are creases 121a, 121 b. The term "outwardly directed" is intended to mean that the fold lines of the creases 121c, 121d are directed away from each other.

As used in this context, the terms "upper" and "lower" are intended to specifically refer to the fold 120 when viewed from the orientation of fig. 5. That is, these terms are not intended to otherwise indicate direction when the fold 120 is oriented for use in an actual product.

Based on these characterizations and comments of fig. 5, it can be seen that the regular folding arrangement 118 according to fig. 5 in this disclosure is a folding arrangement that includes at least two "upper inwardly directed creases. These inwardly directed creases are unique and help provide an overall arrangement in which folding does not cause significant erosion of adjacent flutes.

It can also be seen that the third layer or section 128 is pressed against the second layer or section 124. The third layer or portion 128 is formed by folding opposite the inner ends 130, 131 of the third layer 128.

Another way of viewing the folding arrangement 118 is by reference to the geometry of the alternating ridges and valleys of the corrugated sheet 66. The first layer or portion 122 is formed by an inverted ridge. The second layer or portion 124 corresponds to a double peak folded toward, and in a preferred arrangement against, the inverted ridge (after inverting the ridge).

A technique for providing the alternative indenting described in connection with fig. 5 is described in a preferred manner in PCT WO 04/007054, which is incorporated herein by reference. A technique for winding the media with application of wrapping beads is described in PCT application US 04/07927 filed 3, 17, 2004, which is incorporated herein by reference.

Alternative methods for indenting the grooved ends closed are possible. Such methods may include, for example, indenting that is not centered on each flute, and rolling or folding over different flutes. Generally, staking involves folding or otherwise manipulating the media adjacent the fluted end to achieve a compressed closed state.

The technology described herein is particularly suited to media packs formed by the step of winding a single sheet (i.e., a "single facer" strip) comprising a corrugated sheet/facing sheet combination.

The coiled media pack arrangement may provide a variety of peripheral perimeter definitions. In this context, the term "peripheral perimeter definition" and variants thereof are intended to mean: the defined outer perimeter shape as viewed from the inlet or outlet end of the media pack. A typical shape is circular, as described in PCT WO 04/007054 and PCT application US 04/07927. Other useful shapes are oblong, some examples of which are elliptical shapes. Generally, the oval shape has opposite curved ends attached by a pair of opposite sides. In some elliptical shapes, the opposite side is also curved. In other elliptical shapes (sometimes referred to as racetrack shapes), the opposite side is substantially straight. Racetrack shapes are described, for example, in PCT WO 04/007054 and PCT application US 04/07927, each of which is incorporated herein by reference.

Another way to describe the shape of the outer perimeter or perimeter is by defining a perimeter that results from a cross-section taken through the media pack in a direction orthogonal to the wrap entrance of the wrap.

A variety of different definitions of the opposite flow ends or faces of the media pack may be provided. In many arrangements, the ends are substantially flat and perpendicular to each other. In other arrangements, the end face includes a tapered, convoluted, stepped portion that may be defined as projecting axially outward from an axial end of the sidewall of the media pack; or project axially inward from the ends of the side walls of the media pack.

The fluted seal (e.g., achieved by a single ply bead, a wound bead, or a stack of beads) can be formed from a variety of materials. In different ones of the cited and incorporated references, hot melt seals or polyurethane seals are described as being possible for different applications.

Reference numeral 130 of fig. 6 generally designates a roll-up media pack 130. The rolled media pack 130 comprises a single strip 130a of single facer material comprising a fluted sheet secured to a facing sheet wound around a center, which may include a core, or may be careless (as shown). Typically, the winding is performed with the facing sheet directed outwards. As previously mentioned, a single facing bead and a wrap bead are typically used to provide a fluted seal within the media.

The particular coiled media pack 130 depicted includes an oval media pack 131. It should be noted, however, that the principles described herein may be applied starting with a media pack having a circular configuration.

In fig. 7, the step of forming a stacked z-shaped filter media pack from z-shaped strips of filter media, each strip being a fluted sheet secured to a facing sheet, is schematically illustrated. Referring to fig. 7, a single facer strip 200 is shown as a stack 201 added to a strip 202 similar to strip 200. The strip 200 may be cut from either of the strips 76, 77 (fig. 4). At 205 of fig. 7, the application of stacked beads 206 between each layer corresponding to the strips 200, 202 at the edge opposite the single facer beads or seals is shown. (stacking may also be accomplished by adding each layer to the bottom of the stack rather than the top.)

Referring to fig. 7, each strip 200, 202 has a front edge 207 and a back edge 208 and opposite side edges 209a, 209 b. The inlet and outlet flutes of the corrugated sheet/facing sheet combination comprising each strip 200, 202 extend generally between the leading edge 207 and the trailing edge 208 and parallel to the side edges 209a, 209 b.

Still referring to FIG. 7, in the formed media pack 201, the opposite flow faces are indicated at 210, 211. The choice of which of the faces 210, 211 is the inlet face and which is the outlet face is a matter of choice during filtration. In some cases, the stacked beads 206 are positioned adjacent to the upstream or inlet face 211; and in other cases, the reverse is true. The flow faces 210, 211 extend between opposite side faces 220, 221.

The illustrated stacked media pack 201 formed in fig. 7 is sometimes referred to as a "bulk" stacked media pack. The term "block-shaped" in this context means that the indication arrangement is formed as a rectangular block, wherein all faces are at 90 ° with respect to all adjoining wall faces. Alternative configurations are possible, as discussed below in connection with certain remaining figures. For example, in some cases, the stack may be formed by slightly offsetting the alignment of each strip 200 with adjacent strips to form a parallelogram or inclined block shape in which the inlet and outlet faces are parallel to each other, but not perpendicular to the upper and lower surfaces.

In some instances, the media pack will be referred to as having a parallelogram shape in any cross-section, meaning that any two opposing sides extend generally parallel to each other.

It should be noted that the block-like stacked arrangement corresponding to fig. 7 is described in the prior art of U.S.5,820,646, which is incorporated herein by reference. It should also be noted that the stacked arrangement is described in the following documents: U.S.5,772,883; 5,792,247, respectively; U.S. provisional application 60/457,255 filed on 25/3/2003; and U.S.S.N.10/731,564 filed on 12/8/2003. All four of these subsequent references are incorporated herein by reference. It should be noted that the stacking arrangement shown in u.s.s.n.10/731,504 is a slanted stacking arrangement.

A variety of filter media having upstream and downstream flow faces are contemplated and may be used in different embodiments. Included among the filter media are pleated media forms having flutes defining peaks to reduce masking, such as the media described in patent publication US 2010/0078379, which is incorporated herein by reference.

Alternative types of media arrangements or media packs (including flutes between opposite ends extending therebetween) may be used with selected principles according to the present disclosure. Examples of such alternative media arrangements or media packs are depicted in fig. 8-10. The media of fig. 8 to 10 are similar to the media depicted and described in DE 202008017059U 1; and can sometimes be found in arrangements available under the trade mark "IQORON" from Mann & Hummel, inc.

Referring to FIG. 8, the media or media pack is generally designated 5580. The media or media pack 5580 includes a first outer pleated (ridged) media ring 5581 and a second inner pleated (ridged) media ring 5582, each having pleat tips (or ridges) extending between opposite flow ends. The view of fig. 8 is toward the media pack (flow) end 5585. The depicted end 5585 can be an inlet (inflow) end or an outlet (outflow) end depending on the flow direction selected. For many arrangements using the principles that have been characterized, the media pack 5580 will be configured in a filter cartridge such that the end 5585 is an inlet flow end.

Still referring to fig. 8, the outer pleated (ridged) media ring 5581 is configured in an elliptical shape, but alternatives are possible. At 5590, a pleat end closure, for example molded in place, is depicted closing the end of the pleat or ridge 5581 at the media pack end 5585.

The pleats or ridges 5582 (and associated pleat tips) are positioned to be enclosed by and spaced from the ring 5581, and thus the pleated media ring 5582 is also depicted in a slightly oval configuration. In this example, the ends 5582e of each pleat or ridge 5582p in the ring 5582 are sealed closed. In addition, the ring 5582 surrounds a center 5582c that is closed by a central strip of material 5583, typically molded in place.

During filtration, when the end 5585 is the inlet flow end, air enters the gap 5595 between the two media rings 5581, 5582. Then, as the air moves through the media pack 5580 for filtration, it flows through the ring 5581 or the ring 5582.

In the depicted example, the ring 5581 is configured to slope inwardly toward the ring 5582 and extend away from the end 5585. For structural integrity, spacers 5596 are also shown supporting centering ring 5597 surrounding the ends of ring 5582.

In fig. 9, an end 5586 of the cartridge 5580 opposite the end 5585 is visible. Here, the interior of the ring 5582 surrounding the open gas flow area 5598 can be seen. As air is directed through the cartridge 5580 in a direction generally toward the end 5586 and away from the end 5585, the portion of the air passing through the ring 5582 will enter the central region 5598 and exit therefrom at the end 5586. Of course, air entering the media ring 5581 (fig. 8) will typically pass around (over) the outer perimeter 5586p of the end 5586 during filtration.

In fig. 10, a schematic cross-sectional view of a cartridge 5580 is provided. Selected features identified and described are denoted by the same reference numerals.

As will be understood by reviewing fig. 8-10 described above, the described cartridge 5580 is generally a cartridge having media tips extending in a longitudinal direction between opposing flow ends 5585, 5586.

In the arrangement of fig. 8-10, the media pack 5580 is depicted as having an oval, specifically racetrack-shaped perimeter. Depicted in this manner because the air filter cartridges in many of the examples below also have an oval or racetrack shaped configuration. However, these principles may be embodied in a variety of alternative peripheral shapes.

In fig. 11-18 herein, some schematic partial cross-sectional views of some further alternative variations of media types that may be used in selected applications of the principles characterized herein are provided. Certain examples are described in USSN 62/077,749, filed 11/10 2014 and owned by the assignee doninson Company (Donaldson Company, Inc.) of the present disclosure. In general, each of the arrangements of fig. 12-18 represents a media type that may be stacked or wound into an arrangement having opposing inlet and outlet flow ends (or faces) with straight through flow.

In fig. 11, an example media arrangement 5601 from USSN 62/077,749(2658) is depicted in which an embossed sheet 5602 is secured to a non-embossed sheet 5603, then stacked and wound into a media pack with sealing along opposite edges of the type previously described herein for fig. 1.

In fig. 12, an alternative example media pack 5610 from USSN 62/077,749 is depicted in which a first embossed sheet 5611 is secured to a second embossed sheet 5612, and then formed into a stacked or rolled media pack arrangement having an edge seal generally in accordance with fig. 1 herein.

In fig. 13-15, a third example media arrangement 5620 from USSN 62/077,749 is depicted. The edge sealing may be performed at the upstream end or the downstream end, or in some instances may be performed in both. It may be desirable to avoid typical adhesives or sealants, particularly when the media may encounter chemical materials during filtration.

In fig. 13, a cross-section is depicted in which a fluted sheet X has different embossments thereon for engaging a facing sheet Y. Also, the sheets may be separate or sections of the same media sheet.

In fig. 14, a schematic depiction of such an arrangement between the grooved sheet X and the surface sheet Y is also shown.

In fig. 15, a further variation of this principle between the grooved sheet X and the surface sheet Y is shown. These are intended to aid in understanding how various approaches are possible.

In fig. 16 to 18, another possible variation of the grooved sheet X and the surface sheet Y is shown.

In fig. 16-18, an example media arrangement 5640 is depicted in which a fluted sheet 5642 is secured to a facing sheet 5643. The face sheet 5643 may be a flat sheet. The media arrangement 5640 may then be stacked or wound into a media pack with seals along opposite edges of the type previously described herein with respect to fig. 1. In the illustrated embodiment, the flutes 5644 of the fluted sheet 5642 have an undulating ridge line that includes a series of crests 5645 and saddles 5646. The peaks 5645 of adjacent flutes 5644 can be aligned or offset as shown in fig. 17 and 18. Further, the peak height and/or density can increase, decrease, or remain constant along the length of flute 5644. The ratio of the peak flute height to the saddle flute height can vary from about 1.5 (typically from 1.1) to about 1.

It should be noted that the same media is not specifically required for the fluted sheet section and the facing sheet section. It may be desirable to have different media in each sheet section to achieve different effects. For example, one sheet section may be a cellulosic media, while another sheet section is a media containing some non-cellulosic fibers. They may be provided with different porosities or different structural properties to achieve the desired results.

A variety of materials may be used. For example, the fluted sheet section or the facing sheet section may comprise a cellulosic material, a synthetic material, or a mixture thereof. In some embodiments, one of the fluted sheet section and the facing sheet section comprises a cellulosic material and the other of the fluted sheet section and the facing sheet section comprises a synthetic material.

The synthetic material may comprise polymer fibres such as polyolefin, polyamide, polyester, polyvinyl chloride, polyvinyl alcohol (of different degree of hydrolysis) and polyvinyl acetate fibres. Suitable synthetic fibers include, for example, polyethylene terephthalate, polyethylene, polypropylene, nylon, and rayon. Other suitable synthetic fibers include those made from thermoplastic polymers, cellulose and other fibers coated with thermoplastic polymers, and multicomponent fibers wherein at least one component includes a thermoplastic polymer. Single and multicomponent fibers can be made from polyester, polyethylene, polypropylene, and other conventional thermoplastic fiber materials.

These examples are intended to generally represent a wide variety of alternative media packages that may be used in accordance with the principles herein. Attention should also be directed to USSN 62/077,749, which is incorporated herein by reference, regarding the general principles of construction and application of some alternative media types.

Additional examples of alternative types of media arrangements or media packs involving filter media having flutes extending in a straight-through flow configuration between opposite ends or flow faces are depicted in fig. 19-22. These flutes can be considered inlet flutes when they are arranged to receive dirty air via the inlet flow face, and can be considered outlet flutes when they are arranged to allow filtered air to flow out via the outlet flow face.

The filter media 6502 depicted in fig. 19-21, similar to the filter media depicted in US 8,479,924 and US 9,919,256 assigned to Mann Hummel GmbH, is shown in an arrangement showing how the filter media 6502 may be formed into a media pack arrangement 6504.

The media pack arrangement 6504 may be considered to have relatively long or deep pleats from the inlet flow face 6506 to the outlet flow face 6508, and may also have varying pleat depths as shown. As the pleat depth of the media pack increases, the filter media tend to collapse into each other, resulting in masking. Masking is undesirable because the masked filter media tends to be no longer available for filtration, thereby reducing dust holding capacity and flow through the media pack, and also potentially increasing the pressure drop across the media pack. To reduce masking and help the filter media retain its shape, it is known to apply a support structure to the pleated media. In fig. 20 and 21, a support section or spacer 6510 is provided. It should be understood that fig. 20 and 21 illustrate a pleated configuration 6512 having pleat folds 6514, but are unfolded or separated to illustrate how the filter media 6502 and support sections or spacers 6510 may be arranged.

As shown in fig. 20-21, the filter media 6502 extends between a first side 6516 and a second side 6518. Although only one support section 6510 is shown on each pleat face 6520, it should be understood that multiple support sections 6510 may be disposed along each pleat face 6520 such that when the filter media 6502 is disposed into a media pack (shown as media pack 604 in fig. 19), the volume between each support section 6510 may be considered as flutes extending between the inlet flow face 6506 and the outlet flow face 6508. Support sections 6510 may be disposed on each flow face 6520 such that opposing support sections 6510 contact or engage each other to help maintain the shape of the media pack while also limiting the amount of filter media that the support sections 6510 will contact, as shown in fig. 20. Further, by providing for the support segments 6510 to have adhesive properties, the support segments 6510 may be configured such that opposing support segments 6510 may adhere to one another when the filter media 6502 is disposed into the media pack 6504.

The support section 6510 may be arranged in a tapered configuration, wherein the support section 6510 has a cross-section at the inner fold 6522, and wherein the cross-section increases towards the outer fold 6524. In this context, the phrase "interior fold" refers to the side of the media that forms an acute angle when the media is disposed into a media pack, and the phrase "exterior fold" refers to the side of the media that forms an obtuse angle. Further, reference to changing the cross-section of the support segment 6510 can refer to one or both of the height that the support segment extends away from the media to which it is adhered and the width along the media to which it is adhered in a direction toward or away from other support segments on adjacent flutes. Changing the shape of the support segments 6510 can help maintain the shape of the media pack and the flutes produced, and can help reduce the amount of media that would otherwise be contacted by the support segments 6510 if they were not arranged in a tapered configuration. Additionally, the support sections 6510 may be arranged in a non-tapered configuration. As shown in fig. 21, the support sections 6510 may be arranged such that they extend over the outer fold 6524, but the support sections 6510 need not extend over the outer fold. Additionally, the support sections 6510 need not extend into the interior fold 6522, but the support sections 6510 may be disposed such that they extend into the interior fold 6522, if desired.

When the adhesive is extruded onto the filter media 6502 (where the adhesive forms the support section 6510), the support section 6510 may be applied to the filter media 6502. Before the adhesive has a chance to fully cure, the filter media 6502 may be folded into a media pack arrangement 6504 that may or may not have varying pleat depths. By forming the media pack arrangement 6504 before the adhesive is fully cured, the opposing support sections 6510 may be bonded or adhered to one another, forming flutes extending between the inlet flow face 6506 and the outlet flow face 6508.

It should be understood that the filter media 6502 may have deformations, such as corrugations, extending across the media. The direction of deformation, such as corrugation, may be parallel or perpendicular to the fold folding direction.

The filter media 6602 depicted in fig. 22 is similar to the filter media depicted in US 2018/02007566 assigned to Champion Laboratories, Inc, as another example of a media pack arrangement 6604 having inlet flutes and outlet flutes in a straight-through flow arrangement.

The filter media pack arrangement 6604 may be formed by folding the filter media 6602 to form an inlet flow face 6606 and an outlet flow face 6608. Pleat tips 6610 form an inlet flow face 6606, and pleat tips 6612 form an outlet flow face 6608. The adhesive beads 6616 and 6618, which may be continuous or discontinuous, extend across the filter media 6602 in multiple lines along the filter media 6602 from the media first side 6620 to the media second side 6622. The adhesive beads 6616 and 6618 along the media first side 6620 and along the media second side 6620 may be thickened if desired, and may be arranged to provide an edge seal along the media first side 6620 and the media second side 6622. Inlet flutes 6630 and outlet flutes 6632 may be formed in the straight-through media pack arrangement 6604 by providing beads 6616 and 6618 of adhesive that adhere to each other when the filter media 6602 is folded.

A similar type of filter media pack arrangement is commercially available from Baldwin Filters, Inc. Filter media packs, available from baowei filters, inc under the name of Enduracube, are arranged in a pleated configuration to form inlet flutes and outlet flutes extending between an inlet flow face and an outlet flow face.

Many of the techniques characterized herein will preferably be applied when the media is directed for filtration between opposite flow ends of a filter cartridge, which is media having flute or pleat tips extending in a direction between these opposite ends. However, alternatives are possible. The techniques characterized herein with respect to the seal arrangement definitions can be applied to filter cartridges having opposite flow ends, wherein the media is positioned for filtering fluid flow between these ends, even when the media does not include flute or pleat tips extending in a direction between these ends. For example, the media may be depth media, may be pleated in alternate directions, or may be non-pleated material.

However, the actual situation is: the techniques characterized herein are particularly advantageous for use with filter cartridges that extend relatively deep (typically at least 100mm, typically at least 150mm, often at least 200mm, sometimes at least 250mm, and in some cases 300mm or more) between the flow ends, and are configured for large loading volumes during use. These types of systems will typically be such systems: wherein the media is configured with pleat tips or flutes extending in a direction between the opposite flow ends.

It should also be noted that while the techniques described herein were generally developed for advantageous applications and arrangements involving media packs having straight-through flow configurations, these techniques may be advantageously applied in other systems. These techniques can be applied, for example, when the cartridge includes media surrounding a central interior, wherein the cartridge has open ends. Such an arrangement may involve a "forward flow" in which the air to be filtered enters the central open interior by passing through the media and exits through the open ends; alternatively, in the case of reverse flow, where the air to be filtered enters the open end and then turns around and passes through the media. A variety of such arrangements are possible, including pleated media and alternative types of media. Configurations that may be used would include cylindrical and conical shapes, and the like.

Example air Filter Assembly

A. FIGS. 23 to 35

Attention is now directed to fig. 23. In fig. 23 is a perspective view of an embodiment of an air cleaner assembly 300. The air cleaner assembly 300 includes a housing 302. The housing 302 has an interior volume 304 (fig. 27) and an inlet opening 306 (fig. 26). A cover 308 is removably oriented over the inlet opening 306. The housing 302 communicates with an inlet for air and an outlet for filtered air to be used by the engine, typically a diesel engine.

A filter element 310 (fig. 25) is located within the interior volume 304 of the housing 302. The filter element 310 is located within the housing 302 such that air entering the housing 302 passes through the filter element 310, wherein dust and other debris are removed from the air, and the filtered air then travels downstream of the filter element 310 to an outlet for use by the engine.

Still referring to FIG. 25, filter element 310 is merely one example embodiment. The filter element 310 may be embodied in many different forms. The filter element 310 includes a construction of filter media 312. In this example, the filter media 312 is a z-shaped media 314, as described above in connection with fig. 1-22. Other types of filter media may be used.

The z-shaped media 314 of fig. 25 has opposing flow faces 316, 317. One of the flow faces 316, 317 is an inlet flow face and the other is an outlet flow face. The media pack 312 is configured to filter air flowing into the inlet flow face before the air exits the outlet flow face. In one exemplary embodiment, the inlet flow face is at 317 and the outlet flow face is at 316.

The filter element 312 includes a frame 318. In this embodiment, the frame 318 is mounted to the media pack 312. The frame 318 is positioned on or adjacent to the flow face 316 and surrounds or circumscribes the flow face 316.

A sealing arrangement 320 is positioned on the frame 318. The sealing arrangement 320 comprises a sealing member 322. The sealing member 322 comprises a compressible rubber-like material that forms a releasable seal with the housing 302. The sealing member 322 may be made of a number of materials including, for example, compressible polyurethane foam.

The sealing member 322 may be embodied in many different forms. In the example shown herein, the sealing member 322 is radially directed and is oriented to form a radial seal with the housing. In this case, the radial orientation is a radially outward direction, and in other embodiments, the radial orientation may be a radially inward direction. In still other embodiments, the sealing member 322 may be an axial seal or a pinch seal.

The filter element 310 is racetrack shaped with opposing curved ends 324, 325 joined by opposing straight edges 326, 327. In the illustrated embodiment, the frame 318 and the sealing member 322 are also racetrack shaped.

The frame 318 may include a surface mesh 330 positioned above the flow face 316. The surface mesh 330 may help prevent the filter media 312 from telescoping. The mesh 330 may also help support the sealing member 322.

In accordance with the principles of the present disclosure, the air cleaner assembly 300 includes a two-part mating latch assembly 332 (FIG. 24). The two-part mating latch assembly 332 releasably mates when the filter element 310 is properly and properly installed within the interior volume 304 of the housing 302 and the cover 308 is properly installed in place over the inlet opening 306.

Many embodiments are possible. Generally, the first portion 334 of the two-part mating latch assembly 332 is secured to the cover 308. The second portion 336 of the two-part mating latch assembly 332 is located on one of the housing 302 and the filter element 310.

Generally, the first portion 334 is a latch 340. The latch 340 is shown in fig. 24 as an over-center latch 342. Over center latch 342 includes a lever 344 and a hook 346. The hook 346 is engaged with the second portion 336. Second portion 336 will typically be a retainer 348 for releasable engagement with a hook 346.

In the embodiment of fig. 23-29, the filter element 310 includes a second portion 336 secured thereto. When the filter element 310 is operably mounted within the housing interior volume 304, the second portion 336 extends through the opening 350 in the housing 302.

In fig. 24, the opening 350 is in the form of a pair of apertures 352, 353 extending through the housing 302. The apertures 352, 353 are located adjacent to the inlet opening 306 and the removable cover 308.

Attention is again directed to fig. 25. As previously mentioned, the second portion 336 of the latch assembly 332 may be secured to the filter element 310. In fig. 25, the second portion 336 protrudes from the ear formation 356. An ear formation 356 extends from the frame 318.

A longitudinal axis 358 extends through filter element 310 and through each flow face 316, 317. Generally, the axis 358 is parallel to the sidewall 360 of the filter media pack 312. The second portion 336 protrudes from the ear formation 356 generally parallel to the longitudinal axis 358.

The second portion 336 may be embodied in a number of different forms. In the embodiment of FIG. 25, second portion 336 includes a pair of tabs 362, 363 that are positioned laterally spaced from z-shaped media 314 and project in a direction away from flow faces 316, 317 and z-shaped media 314. The tabs 362, 363 project in a direction away from the remainder of the filter element 310. In the embodiment of FIG. 25, fins 362, 363 are adjacent to flow face 316 and project in a direction opposite to opposite flow face 317.

The ear configuration 356 is shown in fig. 25 as including a pair of ears 366, 367 extending from the frame 318. The ears 366, 367 extend from one side of the frame 318 to be radial or lateral to the frame 318. The ears 366, 367 are generally axially located between the sealing member 322 and the opposing flow face 317.

Each ear 366, 367 includes one of the tabs 362, 363 extending therefrom.

The tabs 362, 363 are sized to be received within the apertures 352, 353. Fig. 26 illustrates one step in installing the filter element 310 into the housing 302. Filter element 310 is mounted through inlet opening 306, which leads to a curved end 325 opposite curved end 324. The bent end 324 is the portion of the filter element 310 adjacent to the ears 366, 367 with tabs 362, 363.

Tabs 362, 363 are sized to interact with first portion 334. In many arrangements, the tabs 362, 363 extend at least 10mm and no greater than 100mm from the ear formation 356; preferably at least 15mm and no greater than 80mm from the ear formation 356.

In fig. 27, the filter element 310 has been installed into the housing 302, and it can be seen that the tabs 362, 363 protrude through apertures 352, 353 in the housing 302. Fig. 28 shows an enlarged view of one of the tabs 362 extending or protruding through the aperture 352.

Fig. 29 shows the final step of joining the two-part mating catch assembly 332. In fig. 29, the first portion 334 mates or engages with the second portion 336. In this embodiment, there are two latches 340, 341. Each of the latches 340, 341 has a hook 346, 347 and a lever 344, 345. The hooks 346, 347 can be seen engaged with tabs 362, 363 which serve as retainers 348, 349.

Fig. 30-35 illustrate another embodiment of an air cleaner assembly 300. The same reference numerals will be used for similar parts. The air cleaner assembly 300 of fig. 30-35 is identical to the air cleaner assembly 300 of fig. 23-29, except for the second portion 336 of the latch assembly 332.

In this embodiment, the second portion 336 is integral with the housing 302. As can be seen in fig. 31, the second portion 336 includes a pair of flanges 370, 371 integral with the housing 302 that are radially outwardly movable from the remainder of the housing 302 when the filter element 310 is operatively mounted within the housing interior volume 304.

In fig. 31, it can be seen that flanges 370, 371 are in a pre-engaged state before filter element 310 has been installed in housing 302. The flanges 370, 371 are adjacent the inlet opening 306 and are angled or sloped in a direction toward the inner volume 304 and away from the outer surface/wall 374 of the housing 302.

When the filter element 310 is operably installed within the housing interior volume 304, the filter element 310 is constructed and arranged to urge the second portion 336 radially outward from the remainder of the housing 302. In this embodiment, the direction in which the filter element 310 is tilted or extends inwardly from the flanges 370, 371 urges the flanges (as shown in fig. 31 and 33) to the position shown in fig. 34 in which the retainers 348, 349 extend outwardly from the housing wall 374.

Fig. 32 shows a filter element 310 that may be used with the embodiment of fig. 30. In this embodiment, the filter element 310 includes a projection arrangement 376 on the ear formation 356. The projection arrangement 376 projects in a direction parallel to the longitudinal axis 358. The filter element 310 in fig. 32 has a frame 318, but for increased clarity, a sealing arrangement 320 that may be mounted or molded on the frame 318 is not depicted.

The protrusion arrangement 376 may include many embodiments. In this embodiment, the projection arrangement 376 includes one or more tabs 378. The tabs 378 are positioned such that when the filter element 310 is operably installed within the housing interior volume 304, the tabs 378 push the flanges 370, 371 radially outward from the remainder of the housing 302 such that the retainers 348, 349 protrude from the housing wall 374. In the example shown in fig. 32, there are two tabs 378 on each ear 366, 367. Many variations are possible.

Fig. 33 illustrates a step in installing the filter element 310 into the housing 302. The illustration in fig. 33 shows the filter element in the interior volume 304 before the element 310 is fully installed, and the flanges 371 still project inwardly in a direction towards their interior volume 304. Fig. 34 shows the element 310 fully installed with the tabs 378 engaged against the flanges 371 such that the retainers 348, 349 project away from the housing wall 374. This places the retainers 348, 349 in a position where they can be engaged or hooked by the hooks 346, 347 of the latches 340, 341.

The engaged position of catch assembly 332 is shown in fig. 35, wherein hooks 346, 347 are grasping or engaging retainers 348, 349. The cover 308 is in position so that the latches 340, 341 can be positioned to mate with the second portion 336 in the form of the flanges 370, 371.

The method of installing the filter element 310 is known from the above. The method includes orienting a filter element 310 into an interior volume 304 of a housing 302 through an inlet opening 306 in the housing 302.

Next, there is the step of orienting the cover 308 over the inlet opening 306.

Next, there is releasably mating the first portion 334 and the second portion 336 of the two-part mating latch assembly 332 to secure the cover 308 to the housing 302. The first portion 334 is secured to the cover 308. The second portion 336 is located on one of the housing 302 and the filter element 310.

The second portion 336 may be an integral part of the housing 302 in the form of flanges 370, 371 that are deflectable from a position extending into the interior volume 304 to a position extending from the remainder of the exterior of the housing 302. The step of orienting the filter element 310 includes pushing the second portion 336 radially outward from the remainder of the housing 302 using the filter element 310.

The filter element 310 may include a second portion 336 secured thereto. For example, the second portion 336 may be in the form of tabs 362, 363 extending from the ear formation 356 of the filter element 310. The step of orienting the filter element 310 includes extending the second portion 336 in the form of tabs 362, 363 through openings 350 (such as apertures 352, 353) in the housing 302 when the filter element 310 is operably mounted within the housing interior volume 304.

B. FIGS. 36 to 42

Attention is now directed to fig. 36-40, which illustrate another embodiment of an air cleaner assembly 300. Air cleaner assembly 300 includes a housing 302 having an interior volume 304 and an inlet opening 306. A cover 308 is removably oriented over the inlet opening 306. The housing 302 communicates with an inlet for air and an outlet for filtered air to be used by the engine, typically a diesel engine.

A filter element 310 is located within the interior volume 304 of the housing 302. The filter element 310 is located within the housing 302 such that air entering the housing 302 passes through the filter element 310, wherein dust and other debris are removed from the air, and the filtered air then travels downstream of the filter element 310 to an outlet for use by the engine. The filter element 310 may be embodied in many different forms. The filter element 310 includes a construction of filter media 312. In this example, the filter media 312 is a z-shaped media 314, as described above in connection with fig. 1-22. Other types of filter media may be used.

As with the previous embodiment, the air cleaner assembly 300 includes a two-part mating latch assembly 332. The two-part mating latch assembly 332 releasably mates when the filter element 310 is properly and properly installed within the interior volume 304 of the housing 302 and the cover 308 is properly installed in place over the inlet opening 306.

In this example, a first portion 334 of the two-part mating latch assembly 332 is secured to the cover 308 and a second portion 336 of the two-part mating latch assembly 332 is located on the housing 302.

The second portion 336 includes a movable interference member embodied as a latch member 500 having a latch tab 501 (fig. 38). Latch member 500 is held by housing 302 such that in a relaxed state, the interference member is in an interference position; that is, when the filter element 310 is not in the housing, the latch member 500 in a relaxed state is angled to prevent connection with the first portion 334 on the cover 308. In the example shown in fig. 38, latch member 500 is angled radially inward such that latch tab 501 extends radially inward toward element 310 and mating latch catch 502 (fig. 40) cannot engage.

When a suitable filter element 310 is installed in housing 302, movable latch member 500 may be moved to a non-interfering position. The filter element 310 includes one or more interference engagement members, embodied herein as plugs 504. The plug 504 projects radially from a sidewall 506 of the filter element 310. There may be the same number of plugs 504 as latching member 500, or there may be fewer plugs 504 than latching member 500. The plug 504 extends along the sidewall 506 only a portion of the sidewall length.

By comparing fig. 38 and 39, it can be appreciated that when the filter element 310 is installed in the housing 302, the plug 504 will engage against the latch member 500 and move the latch member radially outward to position it in a non-interference position for engagement with the latch catch 502 on the cover 308. The cover 308 can be rotated or twisted relative to the housing 302 to move the latching member 502 into secure engagement with the latching tab 501.

If there are no components or if the wrong component is installed in the housing 302, the cover 308 cannot be securely locked to the housing 302 because the latch tab 501 will not be in position for locking engagement.

Fig. 41 and 42 are similar to the embodiment of fig. 38-40, except that there is no plug 504 on the element 310, instead there is a rib 508 that is thinner than the plug 504. The ribs 508 serve as interference engagement members.

C. FIG. 43

In fig. 43, the air cleaner assembly 300 of fig. 29 is shown with a glide track 400. The slide 400 may be part of the cover 308 and used to engage the tabs 362, 363 of the elements.

D. FIGS. 44 to 49

In fig. 44-49, the air cleaner assembly 300 is similar to the assembly 300 of fig. 36-42. Also similar to the embodiment of fig. 36-42, this embodiment includes a filter element 310 that moves the deformable interference member 402 to a non-interfering position once the element 310 is properly installed in the housing 302.

As with the previous embodiment, the air cleaner assembly 300 includes a two-part mating latch assembly 332. The two-part mating latch assembly 332 releasably mates when the filter element 310 is properly and properly installed within the interior volume 304 of the housing 302 and the cover 308 is properly installed in place over the inlet opening 306.

In this example, a first portion 334 of the two-part mating latch assembly 332 is secured to the cover 308 and a second portion 336 of the two-part mating latch assembly 332 is located on the housing 302.

The interference member 402 interferes with the mounting of the cover 308 to the housing 302 prior to the mounting of the element 310. When the element 310 is installed in the housing, movement of the element 310 into the housing 302 will pull the interference member 402 apart and pull the interference apart to allow the cover 308 to mate with the housing 302. When element 310 moves into housing 302 and clears the stop of cap 308, deformable interference member 402 moves radially inward.

Second portion 336 includes an interference member 402 embodied as a flange 512 having an engagement arm 514. Flange 512 is retained by housing 302 such that in a relaxed state, interference member 402 is in an interference position; that is, when the filter element 310 is not in the housing, the flange 512 in a relaxed state is angled to prevent connection with the first portion 334 on the cover 308. In the example shown in fig. 48, the flange 512 is angled radially outward away from the element 310 and the mating catch 513 on the cover 308 cannot engage. Engagement arms 514 extend radially inward toward element 310 and are connected to flange 514 at the base such that the cross-section of flange 512 and arms 514 form a V-shape or U-shape. The radially inward movement of the arms 514 causes the flanges 514 to move radially inward.

When a suitable filter element 310 is installed in the housing 302, the movable flange 512 may be moved to a non-interfering position. The filter element 310 includes an interference engagement member, embodied herein as a plug 504. The plug 504 projects radially from a sidewall 506 of the filter element 310. There may be the same number of plugs 504 as the flange 512, or there may be fewer plugs 504 than the flange 512.

By comparing fig. 48 and 49, it can be appreciated that when the filter element 310 is installed in the housing 302, the plug 504 will engage against the arms 514 and move the arms radially inward, thereby moving the flange 512 radially inward to position it in a non-interference position for engagement with the catches 513 on the cover 308. The cover 308 may be rotated or twisted relative to the housing 302 to move the catch 513 into secure engagement over the flange 512.

If there are no components or if the wrong component is installed in the housing 302, the cover 308 cannot be secured to the housing 302 because the protruding flange 512 will stop the cover 308.

E. FIGS. 50 to 58

In fig. 50-58, the air cleaner assembly 300 is similar to the assembly 300 of fig. 38-42. In this embodiment, once element 310 is properly installed in housing 302, filter element 310 moves the deformable interference member to the non-interfering position.

As with the previous embodiment, the air cleaner assembly 300 includes a two-part mating latch assembly 332. The two-part mating latch assembly 332 releasably mates when the filter element 310 is properly and properly installed within the interior volume 304 of the housing 302 and the cover 308 is properly installed in place over the inlet opening 306.

In this example, a first portion 334 of the two-part mating latch assembly 332 is secured to the cover 308 and a second portion 336 of the two-part mating latch assembly 332 is located on the housing 302.

The filter element 310 has an interference engagement member embodied as a radially outwardly extending plug 504 for pushing the interference member, which is embodied herein as a radially inwardly deflectable flange 404 defined by the housing 302 when the element 310 is installed in the housing 302. Deflectable flange 404 has tabs 405 perpendicular to flange 404. The tab includes a through hole 406. The aperture 406 needs to be aligned and coaxial with an aperture 408 defined in a stationary housing fin 410 extending radially outward from the housing 302.

Fig. 54 shows the axially aligned apertures 406, 408 after the interference member (flange 404) is moved to the non-interference position. The aligned apertures 406, 408 receive a latch member 412 (fig. 55) on the cover 308.

If the element 310 is not properly installed within the housing 302, the deflectable flange 404 will be radially inward (FIG. 53) and the apertures 406, 408 will not align with one another, which will prevent the cover 308 from being properly installed.

Fig. 56-58 are similar to fig. 50-55, except that the plug 504, instead the filter element 310 has ribs 508 that serve as interference engagement members.

In an alternative arrangement, the embodiment of fig. 50-58 may use a radially outwardly extending flange instead of the radially inwardly deflecting flange 404.

F. FIGS. 59 to 60

In the embodiment of fig. 59, the filter element 310 has a rotating member 424 that rotates to move an interference member 426, which then allows the element 310 to be seated within the housing 302 and the cover 308 secured thereto. The rotating member 424 deflects the interference member 426 to allow proper installation.

In the embodiment of fig. 60, latch 428 is shown secured to housing 302, but it may also be secured to cover 308. The interference member 430 will cause interference and prevent the latch 428 from being able to connect the cover 308 to the housing 302 unless the filter element 310 is installed and the interference member 430 is removed from interference. Element 310 pushes down on interference member 430, which causes interference member 430 to rotate or pivot about pivot point 432, and which moves interference member 430 apart to allow cover 308 to be positioned within housing body 302 and to allow latch 428 to secure cover 308 and housing 302 together.

G. FIGS. 61 to 66

In fig. 61-66, the air cleaner assembly 300 is similar to the assembly 300 of fig. 38-42. As with the previous embodiment, in this embodiment, once the element 310 is properly installed in the housing 302, the filter element 310 moves the deformable interference member to the non-interfering position.

The air cleaner assembly 300 includes a two-part mating latch assembly 332. The two-part mating latch assembly 332 releasably mates when the filter element 310 is properly and properly installed within the interior volume 304 of the housing 302 and the cover 308 is properly installed in place over the inlet opening 306.

In this example, a first portion 334 of the two-part mating latch assembly 332 is secured to the cover 308 and a second portion 336 of the two-part mating latch assembly 332 is located on the housing 302.

The filter element 310 has an interference engagement member embodied as a radially outwardly extending plug 504 (which may also be a rib 508) for pushing the interference member, embodied herein as a pivot member 436.

Pivoting member 436 includes an arm 440 that pivots about a hinge point 438. Extending perpendicularly from the arm 440 is a finger 446 having a catch 448. The pivot member 436 prevents the cover 308 and the housing 302 from mating unless the element 310 is properly installed.

When the filter element 310 is installed in the housing 302, the plug 504 pushes the pivot member 436 downward, which will pivot or rotate the arm 440 from the interference (horizontal) position shown in fig. 64 to the non-interference and engagement (vertical) position shown in fig. 65. In the engaged position, the finger 446 extends along a plane perpendicular to the side wall 506 of the member 310, and the catch 448 faces downward and away from the cover 302. This rotation allows the cover 302 and housing 308 to be secured together by the engagement of the latch 442 with the catch 448, as shown in fig. 66.

The foregoing illustrates exemplary principles. Many embodiments can be made using these principles.