WO2009059177A1 - Air cleaner arrangements; components thereof; and, methods - Google Patents

Abstract

A water separator arrangement for use with an air cleaner assembly is depicted. Also an air cleaner assembly having a water separator arrangement thereon, is described. The water separator arrangement generally includes an outer shell and a louver arrangement. The louver arrangement includes a plurality of louver fins. Example louver fins are described. An example water separator assembly which can be disassembled, for replacement of a louver fin therein, is described.

Description

AIR CLEANER ARRANGEMENTS: COMPONENTS THEREOF: AND, METHODS

This application is being filed on 31 October 2008, as a PCT International Patent application in the name of Donaldson Company, Inc., a U.S. national corporation, applicant for the designation of all countries except the US, and Steven K. Campbell, a citizen of the U.S., applicant for the designation of the US only, and claims priority to U.S. Provisional patent application Serial No. 61/001,476, filed November 1, 2007.

Field of the Disclosure

The present disclosure concerns air cleaners for use, for example, for cleaning engine combustion air for vehicles and other equipment. The disclosure provides preferred components, assemblies and methods. The disclosure particularly concerns water separators usable to separate out water entering the air cleaner, along with air to be filtered.

Background

Gas streams often carry particulate material therein. In many instances it is desirable to remove some or all of the particulate material from the gas flow stream. For example, air intake streams to engines for motorized vehicles or power generation equipment often include particulate material therein. The particulate material, should it reach the internal workings of the mechanisms involved, can cause substantial damage. It is therefore preferred, for such systems, to remove the particulate material from the gas flow upstream of the engine or other equipment involved. A variety of air cleaner arrangements have been developed for particulate removal.

There has been a general trend for the utilization of air cleaner arrangements that utilize, as a media pack, z-filter media constructions. In general, z-filter media constructions can be characterized as comprising fluted media sheet materials secured to facing media sheet material, formed in media pack configuration. An example is described in PCT publication WO 2005/107924 published November 17, 2005, incorporated herein by reference. An issue relating to the use of air cleaners such as those described in WO 2005/107924, in some instances, relates to separation out of water, such as rain water, included in the air being drawn into the air cleaner. The present disclosure relates to development and use of advantageous water separator arrangements, for removal of the water as the air is entering the air cleaner.

Summary of the Disclosure

According to the present disclosure a water separator assembly for use with an air cleaner assembly is described. The water separator assembly comprises a shell and a louver arrangement. An arrangement is described, in which the shell and louver arrangement are separable from one another, allowing for the louver arrangement to be changed within the shell as desired.

Example shell arrangements and louver arrangements are described. An air cleaner assembly including a water separator assembly thereon is described. Also described are methods of assembly and use.

Brief Description of the Drawings

Fig. 1 is a fragmentary, schematic, perspective view of an example z- filter media useable in arrangements according to the present disclosure. Fig. 2 is an enlarged schematic, cross-sectional view of a portion of the media depicted in Fig. 1.

Fig. 3 is a schematic view of examples of various corrugated media definitions.

Fig. 4 is a schematic view of a useable process for manufacturing example media according to Fig. 1.

Fig. 5 is an enlarged schematic cross-sectional view of an optional end dart for example media flutes useable in arrangements according to the present disclosure.

Fig. 6 is a schematic, fragmentary, partial cross-sectional, view of an air cleaner assembly, with only selected portions of an internally positioned air filter cartridge viewable.

Fig. 7 is a schematic, inlet end, elevational view of the air cleaner assembly of Fig. 6. Fig. 8 is a schematic side elevational view of a filter cartridge usable in the air cleaner assembly of Figs. 6 and 7.

Fig. 9 is schematic end elevational view of the cartridge of Fig. 8.

Fig. 10 is a schematic, enlarged, fragmentary view of a portion of Fig. 8. Fig. 11 is an enlarged, fragmentary, schematic view of a side portion of an example air cleaner in accord with the present disclosure.

Fig. 12 is a schematic, fragmentary, cross-sectional view taken of an internal portion of the air cleaner of Fig. 11 , with a portion of an installed filter cartridge depicted. Fig. 13 is a schematic side elevational view of an air cleaner depicted with a scavenge duct thereon and also with a water separator arrangement thereon.

Fig. 14 is a schematic, inlet end elevational view of the air cleaner assembly of Fig. 13.

Fig. 15 is a schematic, exploded view of the air cleaner assembly of Fig. 13. Fig. 16 is a schematic, enlarged, top plan view of a water separator assembly according to the present disclosure.

Fig. 17 is a schematic outlet end interior, perspective view of the water separator arrangement of Fig. 16.

Fig. 18 is a schematic, outside, inlet end elevational view of the water separator arrangement of Fig. 17.

Fig. 19 is a schematic, inside elevational view of the water separator arrangement of Fig. 17.

Fig. 20 is schematic, cross-sectional view of the water separator arrangement of Fig. 17; Fig. 20 being taken along line 20-20, Fig. 17. Fig. 21 is a schematic, outside, inlet end, perspective view depicting the water separator of Fig. 16, during a step of assembly.

Fig. 22 is a schematic, interior, perspective view of the assembly of Fig. 21.

Fig. 23 is an additional schematic perspective view of the assembly of Figs. 21 and 22. Fig. 24 is a schematic interior perspective view of a first shell half of the water separator assembly of Fig. 17.

Fig. 25 is a schematic interior view of a second shell half of the water separator assembly of Fig. 17. Fig. 26 is a schematic, outside, inlet face elevational view of a water separator louver arrangement used in the water separator assembly of Fig. 17.

Fig. 27 is a schematic, cross-sectional view taken along line 27-27, Fig. 26.

Fig. 28 is an enlarged, schematic, fragmentary view of a portion of Fig. 27. Fig. 29 is a schematic, interior, perspective view of an alternate water separator assembly according to the present disclosure; selected portions being shown in phantom lines.

Fig. 30 is a schematic, outside, inlet end elevational view of the water separator assembly of Fig. 29. Fig. 31 is a schematic interior elevational view of the water separator assembly of Fig. 29.

Fig. 32 is a schematic outside end elevational view of a louver arrangement of the water separator assembly of Fig. 29.

Fig. 33 is a schematic cross-sectional view taken along line 33-33, Fig. 32. Fig. 34 is an enlarged, schematic, fragmentary view of aportion of Fig. 33.

Detailed Description

I. Z-Filter Media Configurations, Generally. Fluted filter media can be used to provide fluid filter constructions in a variety of manners. One well known manner is as a z-filter construction. The term "z-filter construction" as used herein, is meant to refer to a filter construction in which individual ones of corrugated, folded or otherwise formed filter flutes are used to define longitudinal filter flutes for fluid flow through the media; the fluid flowing along the flutes between opposite inlet and outlet flow ends (or flow faces) of the media. Some examples of z-filter media are provided in U.S. patents 5,820,646; 5,772,883; 5,902,364; 5,792,247; 5,895,574; 6,210,469; 6,190,432; 6,350,296; 6,179,890; 6,235,195; Des. 399,944; Des. 428,128; Des. 396,098; Des. 398,046; and, Des. 437,401; each of these fifteen cited references being incorporated herein by reference.

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

In certain z-filter arrangements, the fluted (typically corrugated) media sheet and the facing media sheet, together, can be used to define media having parallel inlet and outlet flutes. In some instances, the fluted sheet and non-fluted sheet are secured together and are then coiled to form a z-filter media construction. Such arrangements are described, for example, in U.S. 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 one another, to create a filter construction. An example of this is described in Fig. 11 of 5,820,646, incorporated herein by reference.

For specific examples described herein below, coiled arrangements are depicted, although many of the principles can be applied with stacked arrangements. Typically, coiling of the fluted sheet/facing sheet combination around itself, to create a coiled media pack, is conducted with the facing sheet directed outwardly. Some techniques for coiling are described in U.S. provisional application 60/467,521, filed May 2, 2003 and PCT Application US 04/07927, filed March 17, 2004, each of which is incorporated herein by reference. The resulting coiled arrangement generally has, as the outer surface of the media pack, a portion of the facing sheet, as a result.

The term "corrugated" used herein to refer to structure in media, is meant to refer to a flute structure resulting from passing the media between two corrugation rollers, i.e., into a nip or bite between two rollers, each of which has surface features appropriate to cause a corrugation affect in the resulting media. The term "corrugation" is not meant to refer to flutes that are formed by techniques not involving passage of media into a bite between corrugation rollers. However, the term "corrugated" is meant to apply even if the media is further modified or deformed after corrugation, for example by the folding techniques described in PCT WO 04/007054, published January 22, 2004, incorporated herein by reference. Corrugated media is a specific form of fluted media. Fluted media is media which has individual flutes (for example formed by corrugating or folding) extending thereacross.

Serviceable filter element or filter cartridge configurations utilizing z-filter media are sometimes referred to as "straight through flow configurations" or by variants thereof. In general, in this context what is meant is that the serviceable filter elements generally have an inlet flow end (or face) and an opposite exit flow end (or face), with flow entering and exiting the filter cartridge in generally the same straight through direction. (The term "straight through flow configuration" disregards, for this definition, air flow that passes out of the media pack through the outermost wrap of facing media.) The term "serviceable" in this context is meant to refer to a media containing filter cartridge that is periodically removed and replaced from a corresponding air cleaner. In some instances, each of the inlet flow end and outlet flow end will be generally flat or planar, with the two parallel to one another. However, variations from this, for example non-planar faces, are possible in some applications.

A straight through flow configuration (especially for a coiled media pack) is, for example, in contrast to serviceable filter cartridges such as cylindrical pleated filter cartridges of the type shown in U.S. Patent No. 6,039,778, incorporated herein by reference, in which the flow generally makes a substantial turn as its passes through the serviceable cartridge. That is, in a 6,039,778 filter, the flow enters the cylindrical filter cartridge through a cylindrical side, and then turns to exit through an end face (in forward-flow systems). In a typical reverse-flow system, the flow enters the serviceable cylindrical cartridge through an end face and then turns to exit through a side of the cylindrical filter cartridge. An example of such a reverse- flow system is shown in U.S. Patent No. 5,613,992, incorporated by reference herein.

The term "z-filter media construction" and variants thereof as used herein, without more, is meant to refer to any or all of: a web of corrugated or otherwise fluted media secured to (facing) media with appropriate sealing to inhibit air flow from one flow face to another without filtering passage through the filter media; and/or, such a media coiled or otherwise constructed or formed into a three dimensional network of flutes; and/or, a filter construction including such media. In many arrangements, the z-filter media construction is configured for the formation of a network of inlet and outlet flutes, inlet flutes being open at a region adjacent an inlet face and being closed at a region adjacent an outlet face; and, outlet flutes being closed adjacent an inlet face and being open adjacent an outlet face. However, alternative z-filter media arrangements are possible, see for example US 2006/0091084 Al, published May 4, 2006 to Baldwin filters, also comprising flutes extending between opposite flow faces, with a seal arrangement to prevent flow of unfiltered air through the media pack.

In Fig. 1 herein, an example type of media 1 useable as z-filter media is shown. The media 1 is formed from a fluted (in the example corrugated) sheet 3 and a facing sheet 4. hi general, the (fluted corrugated) sheet 3, Fig. 1 is of a type generally characterized herein as having a regular, curved, wave pattern of flutes or corrugations 7. The term "wave pattern" in this context, is meant to refer to a flute or corrugated pattern of alternating troughs 7b and ridges 7a. The term "regular" in this context is meant to refer to the fact that the pairs of troughs and ridges (7b, 7a) alternate with generally the same repeating corrugation (or flute) shape and size. (Also, typically in a regular configuration each trough 7b is substantially an inverse of each ridge 7a.) The term "regular" is thus meant to indicate that the corrugation (or flute) pattern comprises troughs and ridges with each pair (comprising an adjacent trough and ridge) repeating, without substantial modification in size and shape of the corrugations along at least 70% of the length of the flutes. The term "substantial" in this context, refers to a modification resulting from a change in the process or form used to create the corrugated or fluted sheet, as opposed to minor variations from the fact that the media sheet 3 is flexible. With respect to the characterization of a repeating pattern, it is not meant that in any given filter construction, an equal number of ridges and troughs is necessarily present. The media 1 could be terminated, for example, between a pair comprising a ridge and a trough, or partially along a pair comprising a ridge and a trough. (For example, in Fig. 1 the media 1 depicted in fragmentary has eight complete ridges 7a and seven complete troughs 7b.) Also, the opposite flute ends (ends of the troughs and ridges) may vary from one another. Such variations in ends are disregarded in these definitions, unless specifically stated. That is, variations in the ends of flutes are intended to be covered by the above definitions. hi the context of the characterization of a "curved" wave pattern of corrugations, the term "curved" is meant to refer to a corrugation pattern that is not the result of a folded or creased shape provided to the media, but rather the apex 7a of each ridge and the bottom 7b of each trough is formed along a radiused curve. Although alternatives are possible, a typical radius for such z-filter media would be at least 0.25 mm and typically would be not more than 3 mm. (Media that is not curved, by the above definition, can also be useable.)

An additional characteristic of the particular regular, curved, wave pattern depicted in Fig. 1, for the corrugated sheet 3, is that at approximately a midpoint 30 between each trough and each adjacent ridge, along most of the length of the flutes 7, is located a transition region where the curvature inverts. For example, viewing back side or face 3a, Fig. 1, trough 7b is a concave region, and ridge 7a is a convex region. Of course when viewed toward front side or face 3b, trough 7b of side 3 a forms a ridge; and, ridge 7a of face 3 a, forms a trough. (In some instances, region 30 can be a straight segment, instead of a point, with curvature inverting at ends of the segment 30.)

A characteristic of the particular regular, curved, wave pattern corrugated sheet 3 shown in Fig. 1, is that the individual corrugations are generally straight. By "straight" in this context, it is meant that through at least 70% (typically at least 80%) of the length between edges 8 and 9, the ridges 7a and troughs 7b do not change substantially in cross-section. The term "straight" in reference to corrugation pattern shown in Fig. 1, in part distinguishes the pattern from the tapered flutes of corrugated media described in Fig. 1 of WO 97/40918 and PCT Publication WO 03/47722, published June 12, 2003, 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 pattern of straight flutes, as the terms are used herein.

Referring to the present Fig. 1 and as referenced above, the media 1 has first and second opposite edges 8 and 9. For the example shown, when the media 1 is coiled and formed into a media pack, in general edge 9 will form an inlet end for the media pack and edge 8 an outlet end, although an opposite orientation is possible in some applications.

In the example shown, adjacent edge 8 is provided sealant, in this instance in the form of a sealant bead 10, sealing the corrugated (fluted) sheet 3 and the facing sheet 4 together. Bead 10 will sometimes be referred to as a "single facer" bead, since it is a bead between the corrugated sheet 3 and facing sheet 4, which forms the single facer or media strip 1. Sealant bead 10 seals closed individual flutes 11 adjacent edge 8, to passage of air therefrom. hi the example shown, adjacent edge 9 is provided sealant, in this instance in the form of a seal bead 14. Seal bead 14 generally closes flutes 15 to passage of unfiltered fluid therein, adjacent edge 9. Bead 14 would typically be applied as the media 1 is coiled about itself, with the corrugated sheet 3 directed to the inside. Thus, bead 14 will form a seal between a back side 17 of facing sheet 4, and side 18 of the corrugated sheet 3. The bead 14 will sometimes be referred to as a "winding bead" since it is typically applied, as the strip 1 is coiled into a coiled media pack. If the media 1 is cut in strips and stacked, instead of coiled, bead 14 would be a "stacking bead."

Referring to Fig. 1, once the media 1 is incorporated into a media pack, for example by coiling or stacking, it can be operated as follows. First, air in the direction of arrows 12, would enter open flutes 11 adjacent end 9. Due to the closure at end 8, by bead 10, the air would pass through the media shown by arrows 13. It could then exit the media pack, by passage through open ends 15a of the flutes 15, adjacent end 8 of the media pack. Of course operation could be conducted with air flow in the opposite direction. In more general terms, z-filter media comprises fluted filter media secured to facing filter media, and configured in a media pack of flutes extending between first and second opposite flow faces. A sealant or seal arrangement is provided within the media pack, to ensure that air entering flutes at a first upstream edge cannot exit the media pack from a downstream edge, without filtering passage through the media. Alternately stated, a z-filter media is closed to passage of unfiltered air therethrough, between the inlet face and the outlet flow face, typically by a sealant arrangement or other arrangement.

For the particular arrangement shown herein in Fig. 1, the parallel corrugations 7a, 7b are generally straight completely across the media, from edge 8 to edge 9. Straight flutes or corrugations can be deformed or folded at selected locations, especially at ends. Modifications at flute ends for closure are generally disregarded in the above definitions of "regular," "curved" and "wave pattern." Z-filter constructions which do not utilize straight, regular curved wave pattern corrugation (flute) shapes are known. For example in Yamada et al. U.S. 5,562,825 corrugation patterns which utilize somewhat semicircular (in cross section) inlet flutes adjacent narrow V-shaped (with curved sides) exit flutes are shown (see Figs. 1 and 3, of 5,562,825). In Matsumoto, et al. U.S. 5,049,326 circular (in cross-section) or tubular flutes defined by one sheet having half tubes attached to another sheet having half tubes, with flat regions between the resulting parallel, straight, flutes are shown, see Fig. 2 of Matsumoto '326. In Ishii, et al. U.S. 4,925,561 (Fig. 1) flutes folded to have a rectangular cross section are shown, in which the flutes taper along their lengths. In WO 97/40918 (FIG. 1), flutes or parallel corrugations which have a curved, wave patterns (from adjacent curved convex and concave troughs) but which taper along their lengths (and thus are not straight) are shown. Also, in WO 97/40918 flutes which have curved wave patterns, but with different sized ridges and troughs, are shown.

In general, the filter media is a relatively flexible material, typically a non- woven fibrous material (of cellulose fibers, synthetic fibers or both) often including a resin therein, sometimes treated with additional materials. Thus, it can be conformed or configured into the various fluted, for example corrugated, patterns, without unacceptable media damage. Also, it can be readily coiled or otherwise configured for use, again without unacceptable media damage. Of course, it must be of a nature such that it will maintain the required fluted (for example corrugated) configuration, during use.

In the corrugation or fluting process, an inelastic deformation is caused to the media. 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 stretch and bending that has occurred. The facing sheet is sometimes tacked to the fluted sheet, to inhibit this spring back in the fluted (or corrugated) sheet.

Also, typically, the media contains a resin. During the corrugation process, the media can be heated to above the glass transition point of the resin. When the resin then cools, it will help to maintain the fluted shapes. The media of the corrugated sheet 3, facing sheet 4 or both, can be provided with a fine fiber material on one or both sides thereof, for example in accord with U.S. 6,673,136, incorporated herein by reference.

An issue with respect to z-filter constructions relates to closing of the individual flute ends. Typically a sealant or adhesive is provided, to accomplish the closure. As is apparent from the discussion above, in typical z-filter media, especially that which uses straight flutes as opposed to tapered flutes, large sealant surface areas (and volume) at both the upstream end and the downstream end are needed. High quality seals at these locations are critical to proper operation of the media structure that results. The high sealant volume and area creates issues with respect to this.

Still referring to Fig. 1, at 20 tack beads are shown positioned between the corrugated sheet 3 and facing sheet 4, securing the two together. The tack beads 20 can be for example, discontinuous lines of adhesive. The tack beads can also be points in which the media sheets are welded together.

From the above, it will be apparent that the example corrugated sheet 3 depicted is typically not secured continuously to the facing sheet, along the troughs or ridges where the two adjoin. Thus, air can flow between adjacent inlet flutes, and alternately between the adjacent outlet flutes, without passage through the media. However air which has entered in inlet flute cannot exit from an outlet flute, without passing through at least one sheet of media, with filtering.

Attention is now directed to Fig. 2, in which a z-filter media construction 40 utilizing a fluted (in this instance regular, curved, wave pattern corrugated) sheet 43, and a non-corrugated flat, facing, sheet 44, is depicted. The distance Dl, between points 50 and 51, defines the extension of flat media 44 in region 52 underneath a given corrugated flute 53. The length D2 of the arcuate media for the corrugated flute 53, over the same distance Dl is of course larger than Dl, due to the shape of the corrugated flute 53. For a typical regular shaped media used in fluted filter applications, the linear length D2 of the media 53 between points 50 and 51 will generally be at least 1.2 times D 1. Typically, D2 would be within a range of 1.2 - 2.0, inclusive. One particularly convenient arrangement for air filters has a configuration in which D2 is about 1.25 - 1.35 x Dl. Such media has, for example, been used commercially in Donaldson Powercore™ Z-filter arrangements. Herein the ratio D2/D1 will sometimes be characterized as the flute/flat ratio or media draw for the corrugated media.

In the corrugated cardboard industry, various standard flutes have been defined. For example the standard E flute, standard X flute, standard B flute, standard C flute and standard A flute. Figure 3, attached, in combination with Table A below provides definitions of these flutes.

Donaldson Company, hie, (DCI) the assignee of the present disclosure, has used variations of the standard A and standard B flutes, in a variety of z-filter arrangements. These flutes are also defined in Table A and Fig. 3. TABLE A

(Flute definitions for Fig. 3)

DCI A Flute: Flute/flat = 1.52: 1 ; The Radii (R) are as follows:

RlOOO = .0675 inch (1.715 mm); RlOOl = .0581 inch (1.476 mm); R1002 = .0575 inch (1.461 mm); R1003 = .0681 inch (1.730 mm);

DCI B Flute: Flute/flat = 1.32: 1 ; The Radii (R) are as follows:

R1004 = .0600 inch (1.524 mm); R1005 = .0520 inch (1.321 mm); R1006 = .0500 inch (1.270 mm); R1007 = .0620 inch (1.575 mm);

Std. E Flute: Flute/flat = 1.24: 1 ; The Radii (R) are as follows:

R1008 = .0200 inch (.508 mm); Rl 009 = .0300 inch (.762 mm); RlOlO = .0100 inch (.254 mm); RlOIl = .0400 inch (1.016 mm);

Std. X Flute: Flute/flat = 1.29: 1 ; The Radii (R) are as follows:

R1012 = .0250 inch (.635 mm); R1013 = .0150 inch (.381 mm);

Std. B Flute: Flute/flat = 1.29: 1 ; The Radii (R) are as follows:

R1014 = .0410 inch (1.041 mm); R1015 = .0310 inch (.7874 mm); R1016 = .0310 inch (.7874 mm);

Std. C Flute: Flute/flat = 1.46: 1 ; The Radii (R) are as follows:

R1017 = .0720 inch (1.829 mm); R1018 = .0620 inch (1.575 mm);

Std. A Flute: Flute/flat = 1.53 : 1 ; The Radii (R) are as follows:

R1019 = .0720 inch (1.829 mm); Rl 020 = .0620 inch (1.575 mm).

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

Li general, standard flute configurations from the corrugated box industry can be used to define corrugation shapes or approximate corrugation shapes for corrugated media. Comparisons above between the DCI A flute and DCI B flute, and the corrugation industry standard A and standard B flutes, indicate some convenient variations.

II. Manufacture of Coiled Media Configurations Using Fluted Media, Generally. hi Fig. 4, one example of a manufacturing process for making a media strip corresponding to strip 1, Fig. 1 is shown. In general, facing sheet 64 and the fluted (corrugated) sheet 66 having flutes 68 are brought together to form a media web 69, with an adhesive bead located therebetween at 70. The adhesive bead 70 will form a single facer bead 10, Fig. 1. An optional darting process occurs at station 71 to form center darted section 72 located mid-web. The z-filter media or Z-media strip 74 can be cut or slit at 75 along the bead 70 to create two pieces 76, 77 of z-filter media 74, each of which has an edge with a strip of sealant (single facer bead) extending between the corrugating and facing sheet. Of course, if the optional darting process is used, the edge with a strip of sealant (single facer bead) would also have a set of flutes darted at this location.

Techniques for conducting a process as characterized with respect to Fig. 4 are described in PCT WO 04/007054, published January 22, 2004 incorporated herein by reference.

Still in reference to Fig. 4, before the z-filter media 74 is put through the darting station 71 and eventually slit at 75, it must be formed. In the schematic shown in Fig. 4, this is done by passing a sheet of media 92 through a pair of corrugation rollers 94, 95. hi the schematic shown in Fig. 4, the sheet of media 92 is unrolled from a roll 96, wound around tension rollers 98, and then passed through a nip or bite 102 between the corrugation rollers 94, 95. The corrugation rollers 94, 95 have teeth 104 that will give the general desired shape of the corrugations after the flat sheet 92 passes through the nip 102. After passing through the nip 102, the sheet 92 becomes corrugated across the machine direction and is referenced at 66 as the corrugated sheet. The corrugated sheet 66 is then secured to facing sheet 64. (The corrugation process may involve heating the media, in some instances.)

Still in reference to Fig. 4, the process also shows the facing sheet 64 being routed to the darting process station 71. The facing sheet 64 is depicted as being stored on a roll 106 and then directed to the corrugated sheet 66 to form the Z-media 74. The corrugated sheet 66 and the facing sheet 64 would typically be secured together by adhesive or by other means (for example by sonic welding).

Referring to Fig. 4, an adhesive line 70 is shown used, to secure corrugated sheet 66 and facing sheet 64 together, as the sealant bead. Alternatively, the sealant bead for forming the facing bead could be applied as shown as 70a. If the sealant is applied at 70a, it may be desirable to put a gap in the corrugation roller 95, and possibly in both corrugation rollers 94, 95, to accommodate the bead 70a.

Of course the equipment of Fig. 4 can be modified to provide for the tack 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 will be a regular curved wave pattern corrugation, of straight flutes, as defined herein above. A typical regular curved wave pattern used, would be one in which the distance D2, as defined above, in a corrugated pattern is at least 1.2 times the distance Dl as defined above. In example applications, typically D2 = 1.25 - 1.35 x Dl, although alternatives are possible. In some instances the techniques may be applied with curved wave patterns that are not "regular," including, for example, ones that do not use straight flutes. Also, variations from the curved wave patterns shown, are possible.

As described, the process shown in Fig. 4 can be used to create the center darted section 72. Fig. 5 shows, in cross-section, one of the flutes 68 after darting and slitting.

A fold arrangement 118 can be seen to form a darted flute 120 with four creases 121a, 121b, 121c, 121d. The fold arrangement 118 includes a flat first layer or portion 122 that is secured to the facing sheet 64. A second layer or portion 124 is shown pressed against the first layer or portion 122. The second layer or portion 124 is preferably formed from folding opposite 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 meant to indicate that the creases lie on an upper portion of the entire fold 120, when the fold 120 is viewed in the orientation of Fig. 5. The term "inwardly directed" is meant to refer to the fact that the fold line or crease line of each crease 121a, 121b, is directed toward the other.

In Fig. 5, creases 121c, 121d, will generally be referred to herein as "lower, outwardly directed" creases. The term "lower" in this context refers to the fact that the creases 121c, 121d are not located on the top as are creases 121a, 121b, in the orientation of Fig. 5. The term "outwardly directed" is meant to indicate that the fold lines of the creases 121c, 121d are directed away from one another.

The terms "upper" and "lower" as used in this context are meant specifically to refer to the fold 120, when viewed from the orientation of Fig. 5. That is, they are not meant to be otherwise indicative of direction when the fold 120 is oriented in an actual product for use. Based upon these characterizations and review of Fig. 5, it can be seen that a preferred regular fold arrangement 118 according to Fig. 5 in this disclosure is one which includes at least two "upper, inwardly directed, creases." These inwardly directed creases are unique and help provide an overall arrangement in which the folding does not cause a significant encroachment on adjacent flutes.

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

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

Useable techniques for providing the optional dart described in connection with Fig. 5 are described in PCT WO 04/007054, incorporated herein by reference. Techniques for coiling the media, with application of the winding bead, are described in PCT application US 04/07927, filed March 17, 2004 and incorporated herein by reference.

Techniques described herein are particularly well adapted for use in media packs that result from coiling a single sheet comprising a corrugated sheet/facing sheet combination, i.e., a "single facer" strip. Certain of the techniques can be applied with arrangements that, instead of being formed by coiling, are formed from a plurality of strips of single facer.

Coiled media pack arrangements can be provided with a variety of peripheral perimeter definitions. In this context the term "peripheral, perimeter definition" and variants thereof, is meant to refer to the outside perimeter shape defined, looking at either the inlet end or the outlet end of the media pack. Typical shapes are circular as described in PCT WO 04/007054 and PCT application US 04/07927. Other useable shapes are obround, some examples of obround being oval shape, hi general oval shapes have opposite curved side ends attached by a pair of opposite sides, hi some oval shapes, the opposite sides are also curved. In other oval shapes, sometimes called racetrack shapes, the opposite sides are generally straight. Racetrack shapes are described for example in PCT WO 04/007054 and PCT application US 04/07927. Another way of describing the peripheral or perimeter shape is by defining the perimeter resulting from taking a cross-section through the media pack in a direction orthogonal to the winding access of the coil.

Opposite flow ends or flow faces of the media pack can be provided with a variety of different definitions, hi many arrangements, the ends are generally flat and perpendicular to one another, hi other arrangements, the end faces include tapered, coiled, stepped portions which can either be defined to project axially outwardly from an axial end of the side wall of the media pack; or, to project axially inwardly from an end of the side wall of the media pack. The flute seals (for example from the single facer bead, winding bead or stacking bead) can be formed from a variety of materials, hi various ones of the cited and incorporated references, hot melt or polyurethane seals are described as possible for various applications.

III. An Example Improved Air Cleaner Arrangement Utilizing

Z-Filter Media, Figs. 6-12

Figures 6-12 are presented herein, for an understanding of the use to which the water separator invention, characterized below in connection with Figs. 13-34 can be applied. Figs. 6-12 are selected figures taken from US application 11/821,378 filed June 21, 2007, the complete disclosure of which is incorporated herein by reference. Figs. 6-12 relate to an example type of air cleaner which the water separator is particularly adapted to be used.

Fig. 6 is a schematic partially cross-sectional side elevational view of an air cleaner assembly 200. It is noted that in Fig. 6, only a portion of a filter cartridge 250 that would be installed, is depicted. Referring to Fig. 22, the air cleaner 200 includes a housing 201 configured for receipt of a cartridge 250 therein. The cartridge 250 is depicted in Figs. 8 and 9.

It is noted that in Fig. 6, the air cleaner assembly 200 is oriented in a "vertical" orientation, i.e. with access cover pointed upwardly. As is described in WO 2005/017924, analogous assemblies can be constructed and arranged for horizontal mounting (access cover directed toward side). Typically when such is the case, a modified dust drop tube would be used, as discussed in WO 2005/017924.

Referring to Fig. 6, the housing 201 includes an access cover 215 placed on a base section 214. In Fig. 6, a portion of a side wall is removed, for viewing interaction between the air cleaner housing 201 and the projection 251 on cartridge 250. In particular, projection 251 is a first member of a projection/receiver arrangement 255 on cartridge 250. A second member, comprising receiver 257 is also shown, hi operation, projection member 251, when the cartridge 250 is installed, is received within the receiver 257, to provide a coupled projection/receiver arrangement 255, securing the cartridge 250 in place; the projection member 251 engaging a side of receiver 251. Access cover 215 includes tab 258 to provide for secure engagement and thus to avoid rocking or tipping of cartridge 250 out of a sealed or installed position. hi Fig. 6, access cover shown 215 is shown secured in place by latches 216.

The access cover 215 includes a receiver region 231 for receipt of a handle member positioned on cartridge 250.

Referring still to Fig. 6, the air cleaner 200 includes an inlet end 240 with a precleaner arrangement 260 thereon. Air to be filtered flows into the precleaner arrangement 260 through end 260a, in the direction of inlet arrow 261. Dust is removed from the precleaner through downwardly direct dust exit or ejector tube 262. The tube 262 can include an evacuation valve thereover, or be attached to scavenge system. The air then flows into central portion 214 of the air cleaner housing 201, which has, installed therein, air filter cartridge 250. The air flows through cartridge 250 to outlet end 270 of the housing 201. The air then can leave through outlet 271, in the direction of exit arrow 272. hi Fig. 7, an inlet end elevational view of air cleaner 200 is depicted. Inlet end 260a of precleaner 260 is viewable. Precleaner 260 comprises a plurality of separator tubes 265 into which air is directed. Within the separator or cyclonic tubes 261, a preseparation of dust occurs, before the air is passed into the cartridge 250, Fig. 6.

It is desirable to inhibit undesirable amounts of water entering the separator 260. It will be seen from descriptions below with respect to Figs. 13-34, that a water separator arrangement can be attached upstream of the dust preseparator 260. hi Fig. 8, a side elevational view of air filter cartridge 250 is viewable. The cartridge 250 generally comprises a media pack 280, for example comprising an oval, coiled arrangement of z-filter media of the type previously described. The particular cartridge 280 depicted, is provided with a outlet end 281 having a seal arrangement 282 thereon, in the form of an outwardly directed radial seal 282a. Seal arrangement 282, then, in use will install into sealing engagement with a sealing flange or sealing surface of housing 201, forming a housing seal.

Still referring to Fig. 8, cartridge 280 includes band 287 thereon having projection 251 thereon. Typically, an analogous projection would be positioned on opposite side of the cartridge. Handle 258 is also depicted. Handle 258 allows for manipulation of cartridge 250. The handle 258 would be received within receiver 231, Fig. 6, during installation. hi Fig. 9, an inlet end elevational view of the cartridge is shown. The inlet end of the cartridge being depicted at 291. Across end 291 is shown cross brace arrangement 294. Projection member 251a, opposite projection 251, is viewable on Fig. 9.

In Fig. 10, an enlarged, fragmentary view of projection member 251 is depicted. hi Fig. 11, an alternate receiver pocket 257x, to a pocket 257, in a housing is depicted, hi Fig. 12, an alternate projection 258x associated with pocket 257x is shown, securing projection 251 of a cartridge 250. hi general, then, Figs. 6-12 are indicative of general information, relating to an air cleaner assembly. The air cleaner assembly includes a removable and replaceable filter cartridge, comprising z-filter media. The cartridge is loaded into an interior of the air cleaner assembly, through a side access cover. The air cleaner assembly includes a precleaner for inlet air, for dust preseparation. The cartridge is installed with projections on opposite sides thereof extending into a receiver in the housing. An access cover includes appropriate structure to help secure the cartridge from movement once installed. The air cleaner is susceptible to significant amounts of water, for example rain water, being drawn into the separator arrangement, hi Figs. 13-34, features to address this are depicted, hi application, the depicted water separator can remove 80% or more of water entering the air cleaner.

IV. Air Cleaner Assembly with Water Separator Arrangement, Figs.

13-34. A. A First Example Embodiment, Figs. 13-31.

Attention is first directed to Fig. 13, in which an air cleaner assembly 300 is depicted, in side elevational view. The air cleaner assembly 300 maybe generally analogous to air cleaner assembly 200, except for the inclusion of water separator arrangement 340 thereon. It is noted the air cleaner assembly 300 is depicted in a reverse orientation to that shown in Fig. 6. Thus, air enters the air cleaner assembly 300 in a general direction of arrow 301 and leaves in the general direction of arrow 302. The air cleaner assembly 300 includes a housing 305 with an inlet end 306 and an outlet end 307. Outlet 308 is shown allowing filter air to be removed from outlet end 307 in the general direction of arrow 302.

The housing 305 includes a central portion 310 with access cover 311 having handle receiver 312 therein. The access cover 311 is secured in place by latches 313. At 315 , a preseparator is depicted, with dust ej ection tube 316 directed downwardly therefrom. At 317, a vacuum take off for a scavenge arrangement, for removing the dust from preseparator 315 is shown. (Alternatively, an evacuator valve could be positioned on tube 316.)

To facilitate separation of water, for example rain water entrained in air entering the air cleaner assembly 300 in the direction of arrow 301, water separator arrangement 340 is mounted on a remainder of the air cleaner assembly 300, over the housing inlet end 306, in particular at a location over the preseparator 315, with a portion of the preseparator 315 projecting into an interior of the water separator arrangement 340. The water separator assembly 340 includes a lower water evacuation tube 340a depending downwardly therefrom, with evacuator valve 340b, for water removal. hi Fig. 14, an inlet end elevational view of cleaner 300 is depicted. The view is directed toward an inlet side 341 of water separator 340. The inlet side 341 of separator 340 includes a water separator louver arrangement 343 thereat. Attention is now directed to Fig. 15, an exploded, perspective view of air cleaner assembly 300. Referring to Fig. 15, the air cleaner assembly 300 is depicted in an exploded perspective view directed toward outlet 308. An air filter cartridge 250 is viewable operably receivable within interior 305i of housing 305. hi Fig. 15, water separator 340 is shown dismounted from dust preseparator 315. On dust preseparator 315 , bolt receivers 351 are depicted, for receiving bolts 352 which extend through separator 340, for mounting. It is noted that a pair of bolts will be associated with an opposite side of preseparator 315, and the water separator 315, shown in Fig. 13 at 352x. Thus, the particular example arrangement 300 depicted in Fig. 15, the water separator arrangement 340 is removably mounted to the remainder of the air cleaner assembly 300, in particular the water separator assembly 340 is removably mounted over an inlet end 306 of the air cleaner assembly, with the preseparator arrangement 315 projecting into an interior 34Oi of the water separator assembly 340. Gap or recess 36Oz accommodates, and extends partially around, tube 316, Fig. 13.

Attention is now directed to Fig. 16, an enlarged top plan view of water separator 340. Water separator 340 includes a mounting shell 360. For the particular water separator 340 depicted, shell 360 comprises first and second separable shell halves 361, 362.

Fig. 17 is an enlarged inside perspective view of water separator 340. Separator 340 comprises a shell 360; in the example shown having shell halves 361, 362. For the particular example shown, the shell halves 361, 362 are separable from one another, in a manner discussed below. The shell 360 defines a shell interior 360i. In general terms, the shell 360 defines an air flow inlet end 36Ox and an air flow exit end 36Oy. Shell interior surface 36Oi extends around, and defines, an air flow path therethrough; i.e. through the shell 360, from the inlet end 36Ox to the exit end 36Oy. Thus, as air enters the cleaner of assembly 300, it passes into the inlet end 36Ox of the shell 340 and, in due course, exits the exit end 36Oy. Referring to Fig. 17, water separator assembly 340 includes louver arrangement 343 secured to the shell 340, across the air flow path. Louver assembly 343 comprises a plurality of louver fin rows, discussed below. In addition, each louver fin, discussed below, is associated with an air flow path through the louver arrangement, example flow paths being indicated at 343 a, 343b and 343c, in Fig. 17. It is noted that additional air flow paths, not viewable (in Fig. 17) can be present, as discussed below.

Still referring to Fig. 17, air generally enters the water separator 340 in the direction of arrow 370. The air leaves the separator 340 in the general direction of arrow 371, as it enters preseparator 315, Fig. 15. As water passes through the louver arrangement 343, a portion of water carried by the air is collected on an exterior surface 340 of the louver assembly 343, and drains off the louver assembly 343. In addition, as the air passes through the louver assembly 343 and into the valve interior 36Oi, a portion of water carried thereby is collected against the shell interior surface 36Oi, and drains downwardly through lower drain 375. Still referring to Fig. 17, closing interior wall 360i, the shell 360 includes a first water flow stop rib 378, which helps water collecting within interior 360i to drain toward drain 375. Thus, water flow stop rib 378 includes a gap therein at 378g, in which is positioned drain 375. Alternately stated, rib 378 includes ends adjacent to or spaced from, drain 375, on opposite sides thereof.

Interior 36Oi also includes a second water flow stop rib 379. Water flow stop rib 379 generally includes a portion 379x extending along a bottom 360b of shell 360, spaced toward outlet end 36Oy from aperture 375. Section 379x generally inhibits water drainage towards preseparator 315, Fig. 15. Section 379x generally includes no gap therein, or if it is located, as shown in Fig. 17, across joint 379z between shell halves 361, 362, it is gap no more than 2 mm wide, typically no more than 1 mm wide and preferably sections of rib 379 about one another, at interface 379z.

Rib 378 generally extends upwardly along inner wall 36Oi, from regions adjacent to, or spaced from, drain 375. In a typical orientation, rib 378 will be continuous, but for gap 378g, an interface or break where halves of rib 378 engage one another at a top joint 36Ox between sections 361, 362. Thus, for the example shown, rib 378 is generally oval in shape, but for gap 378.

Shell 360 for the example shown generally has an oval shape with opposite curved ends 360a, 360b and opposite sides 360c, 36Od extending therebetween. For the particular example shown, sides 360c, 36Od each includes a central, straight, section; 360e, 36Of, respectively.

Still referring to Fig. 17, rib 379 is generally continuous but for breaks along interfaces between the shell halves 360, 361. Thus, rib 379 is typically oval in shape, corresponding to the shape of shell 360; and generally extends upwardly from lower portion 3601 of shell 360, when orientated for use.

Each of ribs 378, 379 generally projects inwardly, from bowl 36Oi, in relief at least 4 mm, typically at least 6 mm and usually an amount within the range of 6- 12 mm, inclusive. Referring to Fig. 17, shell half 361 includes apertures 380, 381 therein, for receiving bolts 352, Fig. 15, for mounting. Shell aperture 362 correspondingly includes apertures 380x, 38 Ix. For the particular example water separator 340 depicted, apertures 380, 381 are located within straight section 36Oe of shell half

361; and, apertures 38Ox, 381x, are located in straight section 36Of of shell half 362. Attention is now directed to Fig. 18, an end elevational view water separator arrangement 340. An outside (ejector) surface 340 of louver arrangement 343 is viewable. The louver arrangement 343 comprises a plurality (at least two) of louver fin rows 390. The louver fin rows 390 are typically oriented vertically spaced from one another, when the water separator assembly 340 is oriented for use, as shown in Fig. 18. For the particular example louver panel 343 depicted, there are generally six vertically spaced rows 390, numbered 391-396, from lowest to uppermost, in use. In a typical louver arrangement 343 according to the present disclosure, there will be at least two vertically spaced rows 390, typically at least 3, often at least 4 and in most instances a number within the range of 4-8 rows, inclusive.

As indicated above, and generally herein, the terms upper "uppermost" or top and similar terms, are meant to refer to the orientation of the equipment referenced, when oriented for use; and the terms "lower, bottom, lowermost" and variants thereof and similar terms, are also meant to refer to the equipment or feature characterized, with respect to normal orientation for use.

Each row 390 of louver fins comprises at least one louver fin. hi some instances a row comprises a pair of spaced louver fin sections.

Referring to Fig. 18, louver arrangement 343 comprises: lowermost louver fin 400; a next above louver fin 401 ; a next above row comprising a pair 402 of louver fin sections 402a, 402b; a next above louver fin 403; a next above louver fin 404; and, a next above (top) louver fin 405. Louver fin 405, for the example shown, is an uppermost louver fin.

The uppermost louver fin 405 will be discussed first. Above louver fin 405, there is typically no air flow aperture through louver arrangement 343, for flow of air therethrough. Thus, as air impinges on an outer surface 405x of louver fin 405, water will impinge and collect on outer louver surface 405x. This water will generally drain from louver fin 405x downwardly, exteriorly of water separator arrangement 340. Typically as with other louver fins, louver fin 405 extends downwardly and upstream, away from adjacent portion of louver arrangement 343 when oriented for use. This is viewable in Fig. 18, in which louver fin 405 is depicted in cross-section; the cross-section being taken through the assembly 340. Here, louver fin 405 can be seen extending downwardly and outwardly from fin top

405u to lower tip 405t. (Louver arrangement 343 is recessed into a portion of shell 360, to facilitate water collection above fin 405 and around an exterior of louver arrangement 343).

Still referring to Fig. 20, outer surface 405x is typically directed upwardly. Surface 405x may include central, arcuate, section 404y which is generally concave. This concave section 405y is generally curved downwardly and inwardly toward the interior of the shell 360, and upwardly and outwardly away from a remainder of fin 405, Fig. 27. This causes air impinging on outer surface 405x of fin 405, to be generally curved (swept or directed) in a direction upwardly.

To summarize, referring to Fig. 20, a cross-section through water separator assembly 340, louver fin 405 is viewable and a curvature to surface 405x also can be seen. It is preferable that louver arrangement 343 includes no aperture therethrough, above louver fin 405. Thus, air directed against fin 405 will deposit water thereon, and the water will be generally forced up into region 405z as it collects. This water will eventually drain, hi Fig. 20, arcuate section 405, which is a concave section, is viewable. Also, fin 405y can be seen to extend generally downwardly and outwardly, i.e. in an upstream direction, the extension being from upper wall segment 500 of panel 343, downwardly to tip 405t of fin 405.

Still referring to Fig. 20, it is noted that louver arrangement 343 includes an air flow passageway 343m therethrough, under fin 405. Attention is now directed back to Fig. 18. hi Fig. 18 attention is focused on louver fin 404, and next lower louver fin below louver fin 405. Louver fin 404 has an outer surface 404x, with a first rib arrangement 404r extending thereacross. First rib arrangement 404r is generally arcuate, with a convex side directed upwardly and inwardly and a concave side directed downwardly and outwardly. Rib arrangement 404r generally extends completely across outer surface 404x of fin 404.

Herein, when it is said that a convex side of rib, such as rib 404r, is directed upwardly and inwardly, it is meant, generally, that the curve is toward an upper direction and due to the slant of the fin 404, toward an interior of the shell 360. This is shown in Fig. 20. Referring again to Fig. 20, fin 404 can also be seen in cross-section, and central concave 404y is viewable, the concave curve generally being downwardly and inwardly and, thus, facing upwardly and outwardly.

Referring again to Fig. 18, a second rib arrangement 404z is depicted. Rib arrangement 404z generally extends across a wall panel section 501, Fig. 20, above fin 404. In the particular example depicted, rib 404z extends completely across wall section 343b, and is straight and continuous.

Referring to Fig. 20, wall section 501 is generally below aperture 343m and above aperture 343n. Wall section 501 is generally a section from which fin 404 extends downwardly and outwardly, from upper portion 404u to tip 404t. Air flow directed to an exterior surface 404x of fin 404 will generally cause water to impinge on surface 404x. If that water is below rib 401r, the water will tend to drain off tip 404t and drop downwardly, exteriorly of separator 340. If the impingement is above rib 404r, it will be inhibited from upward flow by rib 404z, and will generally drain down fin 404 to location against rib 404r. This water will tend to drain toward opposite side ends 404i, 404j, Fig. 18, of rib 404r. At side ends 404i, 404j, Fig. 18, downwardly turned ends are provided, ending at tips 404rt. This water will generally drain exteriorly of water separator 340.

Referring again to Fig. 20, air entering through aperture 343m, in the general direction of arrow 480 will enter interior 36Oi, still carries some moisture. This moisture will generally be directed against an interior surface 36Oi of shell 360, in region 415 immediately downstream from the louver arrangement 343. Water collected on surface region 415 will tend to drain downwardly toward drain 375. Air movement tend to move the water toward rib 378. However, rib 378 will tend to stop the water from moving any further, to help it drain to drain 375. (Since the louver rows 390 do not extend completely across the shell 360, adjacent surface 360i of shell 360, especially near louver arrangement 340, dead zones to air flow, facilitating moisture separation, are provided.

Any water which passes rib 378, while collected surface 361, will then tend to be driven by air flow direction toward with flow stop rib 379. This rib will tend to inhibit further water flow, and inhibit water drainage downwardly toward drain 375.

Referring to Fig. 18, attention is now directed to fin 403. Fin 403 is generally analogous to fin 404, and is the next fin below fin 403. Thus, fin 403 extends downwardly and outwardly (Fig. 20) from a wall section 502, Fig. 20.

Above wall section 343 of Fig. 20, louver arrangement 343 includes aperture 343n; and below it, aperture 343p. Referring to Fig. 18, fin 403 includes an outer surface 403x with rib 403r extending thereacross. The rib 403r is generally arcuate, with a convex side directed upwardly and inwardly and a concave side directed downwardly and outwardly. The rib 403r extends between opposite sides 403i, 403j, Fig. 18, each of which includes downward turned sections, that terminate in tips 403rt. Further, referring to Fig. 18, extending across wall section 502, is provided horizontal rib 434z. Referring to Fig. 20, fin 403 includes a outer surface 403x with a concave section 403x thereon. Air and water impinging on surface 403x will act analogously to air and water impinging on fin 404. Water impinging below rib 403r will be inhibited from upward migration by rib 403r. Water will tend to drain off tip 403t, outwardly off separator 340. Water impinging above rib 403r but below rib 403z will tend to be inhibited from upward migration by rib 403z. This water will tend to drain on convex or upper side of rib 403r, to opposite sides 403i, 403j, and again downwardly from rib 403, exteriorly of separator 340. Water carried in air passing through aperture 343n will tend to impinge wall section 415, with collection of water thereat. This water will tend to drain downwardly to drain 375, and outwardly from separator 340. The water flow on surface 415 will be inhibited reaching inlet end 36Oy, by first water flow stop rib 378 and second water flow stop rib 379.

Referring to Fig. 18, attention is now directed louver row 402. As previously indicated, louver row 402 comprises two spaced fin sections 402a, 402b. Recessed region 402c is positioned between the fin sections 402a, 402b. The recessed section 402c provides for clearance around structure and an assembly to which air cleaner 300 would be installed.

Fin row 402 extends downwardly and outwardly from wall section 503, Fig. 20. Above wall section 503, is provided aperture 343p, for air flow therethrough. This would be air flow beneath fin 403. Referring to Fig. 18, horizontal rib 402z generally extends across wall section 503.

Fin sections 402a, 402b generally extends downwardly outwardly, from wall section 503. Each has an outer surface 402ax, 402bx, respectively. The outer surface of each generally includes a concave section, analogous to previously discussed fins. Further, each outer surface includes a rib arrangement thereon, for section 402a, rib section 402ar, and for section 402b, rib section 402br. Rib arrangement 402ar generally extends curves downwardly, in an extension away from rib section 402b but toward side end 402i, at which point it then turns downwardly to terminate at tip 402rt. Rib section 402br generally analogously, and oppositely, i.e. downwardly in extension away from rib section 402am to end 402j at which point it turns downwardly to terminate at tip 402rt.

Water impinging on outer surface 402ax below rib section 420ar , will tend to drain downwardly and off tip 402at. Water impinging above rib section 402ar, will tend to be inhibited from upward migration by rib 402z, and will drain downwardly along rib section 402ar, toward side 402i and outwardly on the outside of water separator 340. The water carried by air into aperture 343p, Fig. 20 will tend to be directed against wall section 415, to collect and drain downwardly outwardly through drain 375, with water flow stop rib 378, 379 inhibiting water flow to outlet end 362.

Water impingement on fin section 402b, will analogously be affected.

Referring to Fig. 18, fin 401 is viewable, with outer surface 401x. Fin 401 is the next lower fin, below fin row 402. Fin 401 is a single fin, with outer surface 40 Ix having a arcuate convex section 40 Iy. Fin 401 generally extends downwardly from wall section 504, Fig. 20. Fin 401 extends downwardly and outwardly, as characterized. Portions of fin 401, extend under apertures underneath fin sections 402a, 402b, not viewable in Fig. 20, since the cross-section of Fig. 20 is through recessed section 402c.

Still referring to Fig. 18, fin 401 includes rib 401r extending thereacross, which is arcuate with convex side directed upwardly and inwardly, and with a concave side directed downwardly and outwardly, in extension between opposite sides 401i, 40 Ij. At these points, the rib 401r turns downwardly to terminate at opposite tips 401rt. Positioned in extension across wall section 504, is provided rib 40 Iz. For the example shown, rib 40 Iz is continuous, horizontal and straight. Water impingement upon outer surface 401x of fin 401 will be affected by ribs 401r, 401z analogously to the operation of other previously described fins.

It is noted that below fin 401, air flow aperture 343r through louver arrangement 343 is provided.

Beneath aperture 343r is provided wall section 505 downwardly from which fin 400 extends.

Referring to Fig. 18, fin 400 is a lowermost fin, and has outer surface 400x, which, in the example shown, Fig. 30, has a central, concave, arcuate section 40Oy. Extending across fin surface 40Ox, is provided rib 40Or, depicted as arcuate rib being a convex side directed upwardly and inwardly; and, a concave side directed downwardly and outwardly, in extension between opposite sides 40Oi, 40Oj; at which point the rib 40Or generally turns downwardly, to eventually terminate at tips 400rt.

For the example shown, extending across wall section 505, above fin 400 is provided rib 400z. For the example shown rib 40Oz is horizontal, straight, and continuous.

Referring to Fig. 20, air and water impingement against surface 40Ox will generally drain analogous to that previously discussed.

In Fig. 20, below fin 400, aperture arrangement 343s, through louver arrangement 343 is viewable.

From the above discussions of Figs. 18 and 20, operation of louver arrangement 343 will be understood. The fins are used to facilitate water collection and drainage. The water collection, in part will be on an outside of the individual fins, and outwardly of the water separator 340. Rib arrangements are provided, to facilitate water flow direction exteriorly from the water separator 340.

Fin shapes are selected, to help direct air and water, such that water which is carried to interior 360; is deposited on an interior surface 360i of shell 360, at a region between louver arrangement 343 and an internally positioned water flow stops or ribs 378, 379 This is facilitated by the arcuate (concave) curvature of the various outer surfaces of fins 400-405.

Attention is now is directed to Fig. 19. Li Fig. 19, an interior view of water separator assembly is 340 depicted, taken toward interior side 343i of louver arrangement 343. In Fig. 19, one can view apertures 343m, 343n, 343p, 343r, and 343s. Also viewable are apertures 343q underneath louver sections 402a, 402b. Attention is now directed to Fig. 21. In Fig. 21 , louver separator arrangement 340 is viewable. In Fig. 21, fins 400-405 are viewable, in a perspective view directed toward outer surface 343o. It can be seen that each of the fins 400- 405, has side panels indicated at opposite side panel sets 52Ox, 52Oy. These panels or panel sets 52Ox, 52Oy close sides of individual fins 400-405, to drainage thereunder of the water that has collected drained to the side edges of the louver fins 400-405. As a result of the side closures, fins 400-405 will sometimes be referred to herein as "side closed" louver fins or by similar terms. It is noted that outside of sides 52Ox, 52Oy, water drain paths are provided. Also referring to Fig. 21, the particular water separator arrangement 340 is configured to be disassembled, with a louver arrangement 343, separable therefrom. This allows for differently configured louver arrangement 343 to be positioned within the shell 360. Referring to Fig. 21, shell sections 361, 362 are viewable. Shell section 361 is generally arcuate, with a first end 450 and a second end 451. The first end 450 includes a first hinge member 455 thereon. The second end 451 includes a snap fit projection arrangement 456 thereon.

Still referring to Fig. 21, arcuate section 362 includes first end 460 with a second hinge member 465 thereon. Hinge member 465 is engageable, releasably and rotatably, with hinge member 455. This allows for the arcuate shell sections 361, 362 to swing away from another and toward one another, when engaged. The shell sections 361, 362 can also be separated at the engagement of ends 450, 460.

Referring to shell section 362, opposite to end 460 is provided end 470. End 470 includes a receiving aperture arrangement 471 therein. Receiver arrangement 471 receives a portion of snap fit projection member 456 projection therethrough, when shell 360 is assembled. For the particular example shown, the snap fit projection arrangement 456 comprises two projections, one of which is viewable in Fig. 21; and, receiver arrangement 471 comprises two spaced receivers 471a, 471b.

Still referring to Fig. 21, it is noted that shell section 362 includes a groove arrangement 480 therein, for receiving a peripheral rim 481 of louver arrangement 343. Analogously, shell section 361 includes a groove arrangement 483. During assembly, peripheral rim 481 of louver arrangement 343 can be positioned within the groove 483, 480 of one of shell halves (361, 362), and the other shell half (362, 361) can be closed thereover, receiving a remainder of the peripheral rim 481 in the associated groove.

In Fig. 22, an analogous view of water separator 340 is depicted, only taken toward interior surface 343i of louver arrangement 340. Here, two snap fit projection members 456a, 456b are viewable.

Also from Fig. 22, it can be further understood that opposite sides of the various fin arrangements 400-405 are provided with side closures 502x, 52Oy. Referring to Fig. 22, fin 400 is depicted with opposite side walls 560, 561; fin 401 has opposite side walls 562, 563; fin section 402a has with opposite side walls 565, 566 and; section 402b has opposite side walls 567, 568; fin 403 is provided with opposite side walls 569, 570; fin 404 has opposite side walls 571, 572; and uppermost fin 405 is provided with opposite side end walls 573, 574. The carious side walls, again help direct air flow desirably into interior 46Oi, and further inhibit liquid drainage, along an exterior surface 343x of louver arrangement 343, from draining underneath a fin and into interior 36Oi. Again, opposite sides of the louver fins also define, therebeyond, water drain paths.

In Fig. 23, another view of assembly 340, with one shell section open, is depicted. Again, closed sides to fins 400-405 are viewable.

In Fig. 24, shell section 361 is viewable. In Fig. 25, shell section 362 is viewable. In Fig. 26, an exterior view of louver arrangement 343 is viewable. In Fig.

27, a cross-sectional view taken along line 27-27, Fig. 26 is shown. In Fig. 28, an enlarged view of part of fin 401 is provided. In Fig. 28, rib 401r, analogously to other arcuate ribs, is viewed as having a lower side 800 with an undercut 801. The undercut facilitates water collection below rib 40 Ir.

B. A Second Embodiment, Figs. 29-34

Referring to Fig. 29, water separator assembly 640 is depicted. The water separator assembly 640 includes a shell 660 and louver arrangement 643. Shell 660 defines interior 66Oi. The particular example shell 660 depicted, comprises shell halves 661, 662, which can be removably or releasably secured to one another in manner analogous discussed above, for shell 360. Louver assembly 643 can be analogously secured, removably, within shell 660.

Shell 660 is depicted in a horizontal orientation, for mounting on an air cleaner assembly also mounted horizontally. Internal water flow stop or rib 678 is viewable, having a lower most gap with drain 675 therethrough. Second downstream rib 679 is also viewable. These features are analogous to those previously discussed. Recess or cutaway 680 is configured to position around a portion of a downwardly directed dust drop tube, in a horizontally mounted air cleaner. Apertures 681 facilitate removable engagement with an air cleaner assembly.

Still referring to Fig. 29, water separator assembly 640 includes optional drain aperture 775 and cutaway 780, allowing for use in a vertical orientation. When used in a vertical orientation, an alternate louver arrangement to the one shown at 643 would be used, since, in general a louver arrangement should be oriented with fin rows extending horizontally.

In Fig. 30, an inlet end view of water separator assembly 640 is shown.

Louver arrangement 643 is viewable, comprising individual fin arrangements 700, 701, 702, 703, in a vertical stack. The lowermost fin 700 includes an arcuate rib 710 thereon, positioned underneath a horizontal rib 711 of wall section 712. Above fin

700 is provided a fin 701 comprising a pair of spaced fin arrangements 701a, 701b each having rib arrangement 70 lax, 701bx respectively thereon, above which is wall section 713 with a horizontal rib 714. The next above fin 702 has an outer surface with arcuate rib 702x thereon, above which is positioned rib 702y extending across wall section 720. Above fin

702 is provided fin 703 with an outer surface having an arcuate rib 703x thereon. It is noted that in some instances arcuate rib 703x will be left off, since fin 703 is uppermost. In Fig. 31 , a view directed toward interior side 643i of louver arrangement

643 is depicted.

In Fig. 32, louver arrangement 643 is depicted, separated from shell 660. In

Fig. 33, a cross-sectional view taken along line 33-33, Fig. 32 is provided.

In Fig. 34, an enlarged, fragmentary, cross-section view of louver fin 700, is provided.

C. Example dimensions.

In Fig. 13, some example dimensions are provided as follows: AA = 294.87 mm; AB = 17.83 mm; AC = 69.09 mm; AD = 46.75 mm; AE = 152.4 mm; AF = 64.83 mm; AK = 61.63 mm; AG = 68.05 mm; AH = 114 mm; AI = 156.37 mm; and AJ = 167.45 mm.

In Fig. 14, BA = 130.05 mm; BB = 106.07 mm; BC = 189.34 mm; BD = 42.08 mm; BE = 75.01 mm; BF = 1.91 mm; BG = 32.81 mm; BH = 32.30 mm; BI = 65.62 mm. In Fig. 16, CA = 254 mm; and, CB - 195 mm.

In Fig. 19, DA = 401.32 mm.

In Fig. 20, DB = 38.61 mm; DC = 99.06 mm; and, DD = 25.91 mm.

In Fig. 26, EA = 124.2 mm radius; EB = 127 mm; EC = 14 mm radius; ED =

347.7 mm. In Fig. 28, FA = 50 mm radius (concave radius); FB = 4 mm; FC = 30° (general downward and outward angle); FD = 31.4 mm; FE = 51.6 mm; FF = 6°; FG = 6.5 mm; and, FH = 29.4 mm.

In general terms, the various ribs on the fins, for example fin 40 Ir, Fig. 21 will project outwardly at least 2 mm, usually at least 3 mm and often, as shown, more.

The various horizontal ribs, for example rib 40Oz, Fig. 28, will typically project outwardly at least 2 mm, usually at least 3 mm as shown.

Referring to Fig. 20, typically the water stop rib 378 closest to the louver arrangement 343 will be spaced at least 25 mm therefrom, typically at least 30 mm therefrom and usually an amount within the range 35-50 mm therefrom.

Typically, a second water stop rib 379 is positioned downstream from a first stop rib 378 a distance of at least 20 mm, usually a distance within the range of 20- 40 mm.

In Fig. 31, GA = 401.32 mm.

In Fig. 32, HA = 127.3 mm; and, HB = 127.2 mm radius.

In Fig. 34, IA = 50 mm radius (concave surface radius); IB = 4 mm; IC = 30°; ID = 42.5 mm; IF = 5.1 mm; IE = 5°; and, IH = 29.5 mm. From the examples stated, other dimensions can be taken from scale; and, of course the dimensions can be varied for different sized units.

V. Concluding Comments and Analysis According to the present disclosure, a water separator assembly for use with an air cleaner assembly is provided, hi general terms, the water separator assembly comprises a shell defining an interior surrounding an air flow passageway extending therethrough. In general, the shell defines opposite inlet and outlet air flow ends. The shell defines an inner surface. The shell includes at least one liquid drain therethrough. The liquid drain is a louver drain located in a lower portion of the shell, when oriented for use. The liquid drain generally comprises an aperture engagement through the shell, at a location spaced from both the inlet and outlet air flow ends, of the shell. The shell can be provided in a variety of shapes. An oval shape is depicted, in which the shell has opposite curved ends, with opposite sides extending therebetween. The particular shell depicted has straight sections in middle portions of each of the opposite sides. The shell interior, in the example depicted, includes a first water stop rib arrangement therein. The water stop rib arrangement includes a gap therein, in a lower portion of the shell, oriented for use. The gap is positioned with a first lower drain positioned therein. That is, the first water stop rib generally extends along the shell inner wall upwardly, from locations adjacent to, or spaced from opposite sides of the lower liquid drain. In one example, the first water flow stop rib is generally oval in shape, but for the first lower gap.

Typically the first water stop rib is positioned inwardly, in a downstream direction, from a below characterized louver arrangement.

In an example described, the shell includes a second water flow stop rib therein, positioned spaced from, in a direction generally in an air flow downstream direction, from the first water flow stop rib and the drain. The second water flow stop rib generally extends across the lower portion of the shell , when oriented for use. Typically, there is no gap greater than 2 millimeter, typically no greater than 1 millimeter, in this lower portion of the second water flow stop rib. In the example described, the shell comprises first and second shell halves, removably secured to one another, hi a specific example, each shell half is arcuate. The first shell half has a first end with a first hinge member thereon; and, a second end with a snap-fit projection arrangement thereon. The second arcuate shell half includes a first end with a second hinge member thereon, and a second end with a receiver aperture arrangement thereat. Two shell halves are engaged with: the first hinge member removably and rotatably secured to the second hinge member; and, with the snap-fit projection extending through the receiver aperture arrangement. This provides a snap-fit engagement of the first shell half to the second shell half, which is separable. In the example described, a downstream edge of the shell has an arcuate recess therein, for positioning around a portion of a dust drop tube, when the shell is mounted on an air cleaner assembly, for use.

In a typical water separator assembly according to the present disclosure, a louver arrangement is provided in extension across the air flow passageway. In an example described, the louver arrangement is removably mounted in the shell. In the specific example, the louver arrangement comprises a panel, and the shell halves each include arcuate receiver grooves therein, for extending around a perimeter of the louver panel when mounted. In general, the louver arrangement comprises at least two rows of louver fins extending (mostly but not completely) thereacross, typically at least three rows and often 4-8 rows; inclusive. The rows extend generally horizontally, in use.

The rows of louver fins include at least a first louver fin having an inner surface and an outer surface. The first louver fin, and indeed each louver fin, is generally oriented to project in upstream direction (with respect to air flow) and downwardly, from a remainder (or adjacent portion), of the louver arrangement, when installed for use. In the example described, one or more of the louver fins has an outer or upstream surface, with a convex arcuate section therein.

In examples depicted herein, the louver arrangement includes a wall section adjacent the first louver fin, inwardly and outwardly from which the first louver fin extends. The louver panel arrangement includes an air flow aperture arrangement above the first wall section and the second air flow passage arrangement therethrough, below the first louver fin.

In an example arrangement, a rib arrangement extends across (horizontally in use) the first wall section. In an example depicted, this rib is generally continuous and straight.

In an example depicted, the first louver fin includes a rib extending across an outer surface thereof. This rib, in an example depicted, is arcuate with a convex side directed upwardly and inwardly; and, a concave side directed downwardly and outwardly. In an example depicted, the arcuate rib has opposite ends, with downwardly turned sections.

In the example depicted, one of the louver fin rows comprises two horizontally spaced louver fin sections, with a recess or gap therebetween. A first one of the louver fin sections has an outer concave surface section, with a rib thereon; the rib extending both partially across the first horizontally spaced fin section and depending downwardly in projection away from the second horizontally spaced fin. The second number of pair of horizontally spaced fin section typically has a mirror image rib thereon. Arrangements having a plurality of fins are described. An uppermost fin, in one of the examples, has an outer surface thereof, with no rib thereacross; and, the louver arrangement includes no rib or aperture above the uppermost rib.

It is noted that a water separator assembly can include some or all of the features characterized herein, and be in accord with the present descriptions. That is there is no specific requirement that water separator assembly include all of the features characterized herein, to be in accord with the present teachings.

Herein, an air cleaner assembly is characterized which includes an air cleaner housing having an airflow inlet end and an air flow outlet end. The air cleaner housing defines an interior. The housing includes a removable access cover, providing service access to an interior of the housing.

The air filter cartridge is removably mounted within an interior of the air cleaner housing. The cartridge is operably positioned for filter air flow therethrough, along a flow path from the air flow inlet end to the airflow outlet end of the housing. An example of filter cartridge is shown and described, which comprises a coiled single facer sheet; the single face sheet comprising fluted sheet secured to a facing sheet; the filter being provided, as a result, with a plurality of flutes extending between upstream and downstream ends, and appropriate seals to cause filtering flow of air as it passes through the media. In an example filter cartridge depicted, the downstream end or exit end includes a housing seal arrangement thereon, a specific example depicted comprising an outwardly directed radial seal.

The cartridge can be provided with a band around an upstream end thereof, the band including a handle member thereon. The band can also include a projection arrangement, for engagement with portions of the air cleaner housing, to stabilize the cartridge.

The water separator assembly is mounted over the inlet end of the air cleaner housing. hi an example depicted, the inlet end of the air cleaner housing includes a dust preseparator arrangement thereon, for example comprising a panel including a plurality of cyclonic separators tubes therein. The water separator assembly is mounted with the preseparator assembly projecting into of the shell.

Example arrangements are described, combining an air cleaner oriented, with a longer cross-sectional dimension of the cartridge extending vertically, or alternatively with the longer dimension extending horizontally. In addition a water separator assembly shell is depicted, which includes features adapted for either orientation.

There is no specific requirement that an air cleaner assembly include all of the features characterized herein, in order to obtain some benefit according to the present disclosure.

Claims

What is claimed:

1. A water separator assembly for use with an air cleaner assembly; the water separator assembly comprising:

(a) a shell defining an interior wall surrounding an air flow passageway extending through the shell; and,

(i) the shell having a lower water drain; and,

(b) a louver arrangement extending across the airflow passageway; the louver arrangement including at least two louver fin rows;

(i) a first one of the at least two louver fin rows including a first louver fin having an inner surface and an outer surface;

(A) the louver arrangement including a first wall section extending thereacross;

(B) the louver arrangement including an air flow path therethrough immediately above the first wall section;

(C) the first louver fin being directed upstream and downwardly in extension from the first wall section; and,

(D) the outer surface of the first louver fin having a first rib arrangement extending thereacross.

2. A water separator assembly according to claim 1 wherein:

(a) the first rib arrangement comprises on arcuate rib extending across the first louver fin; the arcuate rib having a convex side directed upwardly and inwardly; and a concave side directed downwardly and outwardly.

3. A water separator assembly according to claim 2 wherein:

(a) the arcuate rib includes first and second, opposite, side ends; and,

(b) the first rib arrangement includes first and second, opposite, downwardly turned end segments extending respectively from the first and second, opposite, arcuate rib extension opposite side ends.

4. A water separator assembly according to any one of claims 1-3 wherein:

(a) the first wall section has a first wall section rib extending thereacross.

5. A water separator assembly according to claim 4 wherein:

(a) the wall section rib extending across the first wall section is straight and continuous.

6. A water separator assembly according to any one of claims 1-5 wherein: (a) the first louver fin outer surface includes a concave section.

7. A water separator assembly according to any one of claims 1-6 wherein: (a) the louver arrangement includes at least four louver fin rows.

8. A water separator assembly according to claim 7 wherein:

(a) the louver arrangement includes an uppermost louver fin having an outer surface with no rib arrangement thereon; and,

(b) the louver arrangement includes no rib or air flow arrangement above the uppermost louver fin.

9. A water separator assembly according to any one of claims 1-8 wherein:

(a) the louver arrangement includes a second wall section above the first wall section;

(b) the first louver fin is a lowermost louver fin; and,

(c) a next louver fin above the first louver fin is a second lowermost louver fin having an inner surface and an outer surface;

(i) the second louver fin being directed upstream and downwardly from a second wall section;

(ii) the louver arrangement including an air flow path therethrough above the second wall section and also an air flow path below the second louver fin; and,

(iii) the outer surface of the second louver fin has a second rib arrangement extending thereacross.

10. A water separator assembly according to claim 9 wherein:

(a) the second rib arrangement comprises a arcuate rib extending across the second louver fin, the arcuate rib having a convex side directed upwardly and inwardly and a concave side directed downwardly and outwardly.

11. A water separator assembly according to claim 10 wherein:

(a) the second wall section includes a second, straight, rib extending thereacross.

12. A water separator assembly according to any one of claims 1-11 wherein:

(a) a selected one of louver fin rows of the louver arrangement includes a pair of horizontally spaced louver fins; (i) the louver arrangement including an air flow path therethrough immediately below each member of the pair of horizontally spaced louver fin section sections; (ii) each member of the pair of horizontally spaced louver fin sections being directed upstream and downwardly from a third wall section; and,

(A) the louver arrangement includes an air flow path therethrough immediately above a third wall section from which spaced louver fins extend; (iii) each member of the pair of horizontally spaced louver fin sections having an inner surface and an outer surface; and, (iv) each member of the pair of horizontally spaced louver fin sections having a rib arrangement on the outer surface thereof.

13. A water separator assembly according to claim 12 wherein:

(a) an outer surface of each member of the pair of horizontally spaced louver fin sections has a concave section.

14. A water separator assembly according to any one of claims 12 and 13 wherein: (a) a first member of the pair of horizontally spaced louver fin sections has a rib extending thereacross at least partially, the rib also depending downwardly in extension in a direction away from the second member of the pair of horizontally spaced louver fin sections; and,

(b) a second member of the pair of horizontally spaced louver fin sections has a rib extending at least partially thereacross that also depends downwardly in extension away from the first member of the pair of horizontally spaced louver fin sections.

15. A water separator arrangement according to any of claims 12-14 wherein: (a) the louver arrangement including a straight, continuous, rib extending across the third wall section immediately above the pair of horizontally spaced louver fin sections.

16. A water separator assembly according to any one of claims 1-15 wherein: (a) the louver arrangement is removably mounted in the shell.

17. A water separator assembly according to any one of claims 1-16 wherein: (a) the shell comprises first and second shell halves releasably secured to one another.

18. A water separator assembly according to any claim 17 wherein:

(a) the shell lower water drain is positioned partially in the first shell half and partially in the second shell half.

19. A water separator assembly according to claim 18 wherein:

(a) the shell includes a first water flow stop rib therein extending along an interior surface of the shell and having a lower gap therein; (i) the water drain being positioned in the lower gap.

20. A water separator assembly according to claim 19 wherein:

(a) the first water flow stop rib is positioned at least 25 mm from the louver arrangement.

21. A water separator assembly according to any one of claims 19-20 wherein: (a) the shell includes a second water flow stop rib positioned downstream, in air flow direction, from both of the first water flow stop rib and the lower water drain.

22. A water separator assembly for use with an air flow assembly; the water separator assembly comprising:

(a) a shell defining an interior surrounding and defining an air flow passageway therethrough;

(i) the shell having a lower water drain; and,

(b) a louver arrangement extending across the air passageway; the louver arrangement including at least two louver fin rows;

(i) a first one of the at least two lower fin rows being a first louver fin having an inner surface and an outer surface;

(A) the louver arrangement including a first wall section with an outside surface extending thereacross immediately above the first louver fin;

(B) the lower arrangement having a rib extending across the first wall section outside surface, above the first louver fin;

(C) the louver arrangement having an air flow path therethrough immediately the first wall section; and,

(D) the first louver fin being directed upstream and downwardly from the first wall section.

23. A water separator assembly according to claim 22 wherein:

(a) the first louver fin outer surface includes a concave section.

24. A water separator assembly according to any one of claim 22 and 23 wherein:

(a) the first louver fin outer surface includes a first rib arrangement thereon and extending thereacross; the first rib arrangement being arcuate with a convex side extending upwardly and inwardly, and a concave side directed downwardly and outwardly.

25. A water separator assembly for use with an air cleaner assembly; the water separator assembly comprising:

(a) a shell defining an interior surrounding an air flow passageway extending therethrough; and,

(i) the shell having a liquid drain; and,

(b) a louver arrangement extending across the air flow passageway, the louver arrangement including at least two louver fin rows;

(i) a first one of the at least two louver fin rows being a first louver fin having an inner surface and an outer surface; (A) the first louver fin being directed upstream and downwardly, and having a concave section on the outer surface.

26. A water separator assembly according to claim 25 wherein:

(a) the first louver fin includes a first rib arrangement extending across the first louver fin outer surface.

27. A water separator assembly for use with an air cleaner assembly; the water separator assembly comprising:

(a) a shell defining an interior surrounding an air flow passageway extending therethrough;

(i) the shell including a lower water drain; and,

(b) a louver arrangement removably secured to the shell; the louver arrangement extending across the air flow passageway and including at least two louver fin rows.

28. A water separator assembly according to claim 27 wherein:

(a) the shell comprises two shell halves releasably secured to one another; the two shell halves defining a retention groove for receipt therein of an outer perimeter of the louver arrangement.

29. A water separator assembly according to any one of claims 27 and 28 wherein: (a) the shell comprises a first arcuate shell half and a second arcuate shell half; (i) the first arcuate shell half having a first end with a first hinge member and a second end with a snap fit arrangement; and, (ii) the second arcuate shell half has a first end with a second hinge member and a second end with a receiver aperture arrangement;

(A) the first arcuate shell half being secured to the second arcuate shell half with:

(1) the first hinge member releasably secured to the second hinge member; and,

(2) the snap fit hook arrangement releasably projecting into the receiver aperture arrangement.

30. A water separator assembly according to any one of claims 27-29 wherein:

(a) the shell includes a first water flow stop rib therein extending along the shell interior and having a lower gap therein, in which is positioned the water drain.

31. A water separator assembly according to claim 30 wherein:

(a) the shell includes a second water flow stop rib positioned at a location spaced, in an air flow direction downstream, from both of the first water flow stop rib and the water drain.

32. A water separator assembly for use with an air cleaner assembly; the water separator assembly comprising:

(a) a shell defining an interior surrounding an air flow passageway extending therethrough; (i) the shell including a lower liquid drain; (ii) the shell including a first water flow stop rib therein;

(A) the first water flow stop rib having a first lower gap therein; the lower liquid drain being positioned in the first lower gap; and, (B) the first water flow stop rib extending along opposite interior sides of the shell from the first lower gap; and, (b) a louver arrangement extending across the air flow passageway upstream from the first lower gap and the lower liquid drain.

33. A water separator assembly according to claim 32 including:

(a) a second water flow stop rib positioned at a location spaced, in an air flow direction, downstream from the first water flow stop rib.

34. A water separator assembly according to claim 33 wherein:

(a) the second water flow stop rib includes a lower section having no water flow gap therein greater than 2 mm wide.

35. A air cleaner assembly comprising:

(a) an air cleaner assembly having: an air flow inlet end; and, an air flow outlet end,

(i) the air cleaner housing defining an interior and having a removable access cover;

(b) an air filter cartridge removably mounted within the interior of the air cleaner housing; and,

(c) a water separator assembly in accord with at least one of claims 1-35 operably positioned over the inlet end of the air cleaner housing.

36. An air cleaner assembly according to claim 35 wherein:

(a) the air cleaner housing inlet end comprises a precleaner; and,

(b) the water separator assembly is mounted on the precleaner with a portion of the precleaner projecting into the shell.

37. An air cleaner assembly according to any one of claims 35 and 36 wherein: (a) the water separator assembly is removably attached to a remainder of the air cleaner assembly.

8. An air cleaner assembly according to any one of claims 35-37 wherein:

(a) the air cleaner housing includes a downwardly projecting dust ejection tube; and,

(b) the shell of the water separator assembly includes an arcuate recess shaped to fit at least partially around the dust ejection tube.