Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
  • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
  • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
  • B01D46/2411—Filter cartridges
  • B01D46/2414—End caps including additional functions or special forms
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
  • B01D46/42—Auxiliary equipment or operation thereof
  • B01D46/4227—Manipulating filters or filter elements, e.g. handles or extracting tools

Definitions

• the present disclosure relates to a filter element, for instance an air filter element for filtering a fluid, for instance a filter for the intake air of an internal combustion engine.
• US patent US 7,267,706 discloses an air filter for purifying combustion air for an internal combustion engine, comprising an essentially metal-free filter insert which forms a hollow cylinder having end disks arranged on the axial end faces of the filter medium of the filter insert, one end having a handle element extending axially away from the filter element and the other end disk being constructed as a hollow cylinder having a concentric, radially acting, elastic gasket.
• Filter elements are positioned in a filter housing.
• the handle element of US 7,267,706 has the disadvantage that it extends the length of the filter element, thereby reducing the available length for applying filter medium. For a predetermined housing length, the amount of media is thus reduced when compared to a similar element which does not comprise such a handle.
• the disclosed handle element is moreover rigid and non-deformable. Production of these elements is relatively costly as a number of subsequent process steps are to be performed. Another disadvantage is that the handle element can unwantedly interact with obstacles during servicing.
• a filter element which comprises a filter medium, the filter element comprising a first end cap at a first axial end, the end cap defining an end surface of the filter element and further comprising a resilient pulling means (or pulling arrangement, or resilient handle, or device) for removing the filter element from a respective filter housing.
• the pulling means does not extend above the end surface.
• the end surface is a substantially planar surface.
• the pulling means is positioned fully below the planar end surface.
• an upper surface of the pulling means abuts on the planar end surface.
• the filter medium defines an internal volume of the filter element and the pulling means is at least partially, or completely, comprised within the internal volume.
• the filter medium is embedded in the end cap at a first end of the filter medium. This can be the result of an over molding process.
• the end surface is parallel to a planar surface defined by a corresponding axial end of the filter medium in the first end cap.
• the planar end surface is oriented perpendicularly on a symmetry axis of the filter medium.
• the pulling means is arranged and adapted such that when a pulling action is performed on the pulling means, e.g. with a force suitable for removing the filter element from a sealing position in a housing, the pulling means at least partially extends above the (e.g. planar) end surface.
• the pulling means comprises at least one pulling flap or handle portion which extends perpendicular to the axial direction of the filter element.
• the pulling means forms an integral part of the first end cap, the first end cap comprising a flexible material embedding an axial end portion of the filter medium.
• the end cap including the pulling means consists of a such a flexible material, and is preferable formed in a single step.
• the first end cap and pulling means comprise or consist of polyurethane (PU; e.g. foamable or non-foamable) and/or thermoplastic elastomer (TPE) and/or other suitable material known to the skilled person. Rubber and silicone can also be utilized as suitable materials.
• PU polyurethane
• TPE thermoplastic elastomer
• the first end cap is rigid except for the pulling means.
• the first end cap can be made of a hard plastic and can comprise a pulling flap made of an elastically deformable material, such as for instance a thermoplastic elastomer.
• the plastic end cap can for instance be sealingly bonded as for instance glued or potted to the media and if present the inner and/or outer liners.
• the filter element further comprises at least one of an inner liner and an outer liner surrounding and supporting the filter medium, wherein the first end cap further embeds an axial end portion of the inner and/or outer liner.
• inner liner, outer liner and filter medium can abut on a common planar surface.
• the pulling means comprises a gripping structure arranged within a recess in the end surface of the first end cap.
• the recess can extend into the internal volume, e.g. from the planar end surface of the end cap.
• the pulling means comprises at least one cantilevered pulling flap or handle portion arranged within the recess in the first end cap.
• the recess and the cantilevered pulling flap(s) are adapted and arranged such that it allows a finger to reach below the cantilevered flap within the recess, such as an average adult male thumb or index finger.
• the cantilevered pulling flap is further adapted for allowing a pulling force to be applied on the filter element which is larger than the force needed for removing the filter element from the housing, i.e. for breaking the seal formed by the other/second end cap positioned at a second axial end with the housing.
• the pulling flap comprises an inwardly oriented, or concave, arcuate section which together with the inner side wall of the recess defines an opening that allows a finger to pass through while moving into a pulling position below the cantilevered flap.
• an upper surface of the pulling flap is substantially parallel to, or lies within, the planar end surface of the first end cap.
• a surface of the gripping structure e.g. the pulling flap, e.g. an upper and/or lower surface thereof, comprises anti-slip features.
• the filter element further comprises a first set of at least three recesses in an outer radial surface of the first endcap, axially extending from the end surface up to a level beyond the respective end surface of the filter medium.
• These recesses can be regularly arranged , for instance at constant angular intervals.
• the recesses preferably abut, with their radially most inwardly extending surface, to the outer surface of the outer liner.
• the first end cap is preferably closed, i.e. it does not allow fluid as for instance air to enter the internal cavity from the first end cap portion.
• the filter element further comprises a second set of at least three recesses in an outer radial surface of the first endcap, axially extending from the end surface and abutting on the respective end surface of the filter medium.
• the filter element further comprises a second end cap, at an axial end opposite to the first end cap, the second end cap comprising sealing means as a seal or gasket and being adapted for sealing against a fluid channel within a housing.
• the second end cap is preferably open. It can comprise an elastic gasket which is radially and/or axially acting.
• the seal can have a radially directed component, e.g. it can be radially directed, for instance inwardly or outwardly. It can also have an axially directed component or be an axially directed seal.
• a filter assembly comprising a housing and a filter element according to any of the embodiments of the first aspect, arranged within the housing, wherein the housing does not allow lateral access to the filter element when servicing the element.
• the medium is of the tube-type. It can for instance comprise a cylinder-shape or conical envelope.
• the filter element can for instance be a main filter element or a safety element in an air intake system for an engine.
• the filter element includes a filter medium extending between a first axial end and a second axial end, a first end cap disposed at the filter medium first axial end and extending between a base end and a distal end, and a resilient handle formed within the first end cap and being elastically deflectable with respect to a remaining portion of the first end cap, wherein the resilient handle is for removing said filter element from a respective filter housing.
• the resilient handle is located between the base end and the distal end of the first end cap when the resilient handle is in a resting state.
• At least a portion of the resilient handle is located within an interior volume defined by the filter medium.
• At least a portion of the resilient handle extends beyond the distal end of the first end cap when the resilient handle is in a deflected state.
• the end cap and resilient handle are formed from a polyurethane material. In some examples, the end cap and resilient handle are formed from rubber or silicone.
• the filter element additionally includes at least one of an inner liner and an outer liner surrounding and supporting said filter medium.
• the first end cap further embeds an axial end portion of said inner and/or outer liner.
• the resilient handle is provided with an anti- slip feature on one or both of a first side and a second side of the resilient handle.
• the resilient handle includes a base portion and a cantilevered handle portion, the base portion connecting the first end cap to the cantilevered handle portion.
• the cantilevered handle portion is spaced from the first end cap to allow a finger to reach between the cantilevered handle portion and the first end cap.
• the resilient handle includes a plurality of radially arranged resilient handles.
• Fig. 1 is a perspective view of a filter element according to embodiments of the present invention.
• FIG. 2 is a perspective view of a filter element according to embodiments of the present invention.
• Fig. 3 is an exploded view of the embodiment depicted in Fig 2.
• Fig. 4 is a top view of the first end cap of the embodiment depicted in Fig. 2.
• Fig. 5 is a cross section view of embodiments illustrated in Fig. 1 and Fig. 2.
• Fig. 6 is a detail of the cross section view of Fig. 5.
• Fig. 6A is a detail of the cross section view of Fig. 5 showing the resilient pulling means of the filter element in a deflected state.
• Fig. 7a illustrates a further embodiment of the present disclosure, in perspective view.
• Fig. 7b is a cross-sectional view of the embodiment depicted in Fig. 7a.
• FIG. 8 is a top view of a further embodiment of the disclosure, wherein two pulling means are provided on a closed end cap.
• FIG. 9 is a top view of a further embodiment of the disclosure, wherein four pulling means are provided on a closed end cap.
• FIG. 10 is a top view of a further embodiment of the disclosure, wherein four pulling means are provided on a closed end cap.
• FIG. 11 is a top view of a further embodiment of the disclosure, wherein two pulling means are provided on only one half of the closed end cap.
• FIG. 12 is a top view of a further embodiment of the disclosure, wherein two pulling means are provided on a closed end cap, wherein the pulling means face away from each other and the center of the end cap.
• FIG. 13 is a top view of a further embodiment of the disclosure, wherein four pulling means are provided on a closed end cap and share a common support ring.
• Figures 1 and 2 are perspective views of a filter element 1 according to embodiments of the present invention.
• the embodiments depicted in Fig. 2 differs from the embodiment described in relation with Fig. 1 only in the presence of recesses 23 and 22 which will be explained further.
• Figure 3 is an exploded view of the
• the filter element 1 is of the tube type. It comprises a filter medium 5 defining a cylinder extending between first and second axial ends 5a, 5b.
• the filter medium defines an internal volume 7.
• the filter medium 5 can be provided as any type of media, such as media commonly used in filter elements. Exemplary media include pleated media, non-pleated media (such as non-woven media), fluted media, and multilayer laminate.
• the shape can be conical or any other shape defining an internal volume along a longitudinal axis.
• An outer liner 4 is provided around the filter medium 5, supporting the filter medium 5 externally, but this is not necessary.
• An inner liner 6 is provided for supporting the filter medium 5 internally, but this is not strictly necessary. In some examples no liner is provided.
• the filter element 1 includes a first end cap 2 at a first axial end 5a of the filter medium 5. In one aspect, the end cap 2 extends between a base end 2b and a first distal end 2a defining an end surface 200.
• the filter element 1 also includes a second end cap 3 at a second, opposing axial end 5b of the filter medium 5.
• the first end cap 2 further comprises a resilient pulling means 21 (e.g. pulling portion, flap 211 with support 210, or resilient handle 210/211) for removing the filter element from a respective filter housing (not depicted).
• the pulling means 21 does not extend past the first distal end 2a or above the end surface 200, which is preferably planar (See Fig. 5, 200P). In the example shown, the pulling means 21 abuts on the planar end surface 200.
• the pulling means 21 can be positioned fully below the planar end surface 200 such that the distal end 2a extend beyond the pulling means 21.
• the end surface 200 is parallel to a planar surface defined by a corresponding axial end 5a of the filter medium 5.
• the planar end surface is oriented perpendicular on a symmetry axis of the filter 1 or filter medium 5, as illustrated.
• the filter medium 5 defines an internal volume 7 of the filter element and the pulling means 21 is partially comprised within the internal volume 7.
• the pulling means can also be completely comprised in the internal volume 7.
• the filter medium 5 is embedded in the first end cap 2 at a first end of the filter medium 5.
• the pulling means 21 forms an integral part of the first end cap 2, wherein the first end cap 2 includes a flexible, non-rigid material embedding an axial end portion of the filter medium 5.
• a suitable material as for instance polyurethane or thermoplastic elastomer material
• Rubber and silicone can also be utilized as suitable materials.
• the pulling means 21 or resilient handle 210, 211, or flap 210, 211 is arranged and adapted such that, when a pulling action is performed on the pulling means, the pulling means 21 (or handle portion or flap 211) deforms or deflects essentially elastically and extends at least partially above the plane 200P defined by the planar end surface 200, as is shown schematically at reference 21a in Fig. 6A. In that position, a pulling force suitable for removing the filter element 1 from a sealing position in a housing can then be applied.
• the fact that the pulling means 21 (e.g. handle portion or flap 211) is resilient will cause it to move back inwardly when released, and no substantial overall deformation of the pulling means 21 will take place during that process.
• the filter element will thereby retain an unused appearance.
• the pulling means is resilient, it will not remain in a deformed state projecting away from the first end cap. It thus reduces unsought interaction with obstacles within the engine area or servicing space.
• the resilience of the pulling means 2 is also important in relation with the preferred production process as described in the previous paragraph. It was surprisingly found that when using a suitable material, e.g. polyurethane or similar materials such as rubber or silicone, the pulling means can be formed integrally with the rest of the first end cap 2.
• the pulling means is embodied as a handle or pulling flap 210, 211 which has a cantilevered component or portion 211, for instance extending in a direction substantially perpendicular to the axial direction of the filter element, the resilience/flexibility of the material does allow the removal of the first end cap 2 from the mold without damage to the endcap/pulling means, even if the radially cantilevered portion is initially hooked into the mold.
• the pulling means 21 for instance a cantilevered handle portion or pulling flap 211 and base or support 210, is arranged within a recess 20 in the end surface 200 of the first end cap 2.
• the recess 20 can extend into the internal volume 7, e.g. from the planar end surface 200 of the end cap 2, as illustrated for instance in Fig. 4.
• the pulling means 21 or resilient handle 210, 211, or flap 210, 211 was found to easily provide a sufficient tactile surface with sufficient strength to enable an operator to sufficiently grasp and pull the filter element from a housing without requiring additional grasping features such as a finger gripping aperture or void extending through a portion of the pulling means 21 or resilient handle 210, 211, or flap 210, 211.
• additional components such as ring structures or grommets, are not required by the disclosed pulling means 21, thereby allowing the pulling means 21 to be unitarily formed with the end cap 2 from a single material.
• the second end cap 3 at an axial end opposite to the first end cap is provided with a sealing means, such as a seal or gasket and is adapted for sealing against a fluid channel within a housing.
• the second end cap is preferably open and has a filter outlet/inlet opening 30.
• the second end cap 3 has an end surface, for instance a planar end surface 300 abutting on a plane 300P.
• the seal can have a radially directed component, e.g. it can be radially directed, for instance inwardly or outwardly. It can also have an axially directed component or be an axially directed seal.
• radially oriented protrusions 32 and grooves 33 may be present in the internal and external surface of the gasket, as a result of the alignment features in the mold.
• the second end cap can be formed by a similar potting technique as the first end cap, and can comprise similar materials, as for instance PU or TPE.
• the recess 20 and the cantilevered handle portion or pulling flap(s) and support(s) 211, 210 are adapted and arranged such that it allows a finger to reach below the cantilevered flap 211 within the recess 20, such as an average adult male thumb or index finger.
• the cantilevered pulling flap 211 is further adapted for allowing a pulling force to be applied on the filter element which is larger than the force needed for removing the filter element from the housing, i.e. for breaking the seal formed by the other/second end cap 3 positioned at a second axial end.
• the pulling flap 211 comprises an inwardly oriented, or concave, arcuate section 213 which together with the inner side wall of the recess defines an opening 202 that allows a finger to pass through while moving into a pulling position below the cantilevered flap.
• a surface of the gripping structure e.g. the pulling flap, e.g. an upper and/or lower surface thereof, can comprise anti-slip features 212, which improve grip of the fingers on the pulling means/flap 21.
• the anti-slip features 212 include a plurality of spaced apart ribs.
• Other suitable anti-slip features include knurling, indentations, and protrusions.
• the first end cap 2 is preferably closed, i.e. it does not allow fluid as for instance air to enter the internal cavity from the first end cap side.
• the filter element further comprises a first set of at least three, in this case six, recesses 23 in an outer radial surface of the first endcap 2, axially extending from the end surface 200 up to a level beyond the respective end surface of the filter medium 5.
• These recesses can be artefacts of a preferred production process for the filter element, which is based on a potting technique and has been described before. Indeed, positioning features as ribs or protrusions can be present in the mold, which allow for a correct, e.g. axially centered positioning of the filter media (and optionally liners) into the mold after applying the endcap material, and which result in the recesses 23 in the first endcap 2 after demolding.
• These recesses 23 can be regularly arranged, for instance at constant angular intervals. The recesses then preferably abut, with their radially most inwardly extending surface, to the outer surface of the filter medium 5, or outer liner 4 if present.
• the filter element further comprises a second set of at least three recesses 24 in an outer radial surface of the first endcap 2, axially extending from the end surface 200 and abutting on the respective end surface of the filter medium 5 (and/or on the end surface of the liners 4 and/or 6 if present).
• These recesses can be artefacts of a preferred production process for the filter element, which is based on a potting technique and has been described before. Indeed, distance keeping features as ribs or protrusions can be present in the mold, providing a support for the filter medium 5 and optionally liners 4 and 6 in the mold at a certain vertical distance from the bottom of the mold. After applying the endcap material, this results in the recesses 24 in the first endcap 2 after demolding. Note that the axial extent for the recesses 24 is smaller than the axial extent of the recesses 23.
• These recesses 24 can be regularly arranged, for instance at constant angular intervals.
• the recesses then preferably abut, with their axial end surface, to the end surface of the filter medium 5, or liners 4 and/or 6 if present.
• Some or all of the recesses 23 and 24 may have corresponding angular positions. In such case the number of interruptions in the endcap can be reduced.
• the number of recesses 23 is larger than the number of recesses 24.
• Fig. 6 illustrates some more details of the first end cap 2.
• the endcap 2 comprises a recess 20, wherein a pulling means 21 is arranged.
• the pulling means 21 comprises a cantilevered pulling flap or handle portion 211, which is supported by a base 210.
• the handle portion or pulling flap 211 has a tapered cross-section with the handle portion or flap 211 having a greater width near the base 210. This shape results in a greater space being provided between the distal end of the handle portion or pulling flap 211 and the underlying bottom surface of the end cap 2, which can allow a user to more easily insert a finger beneath the handle portion or pulling flap.
• the bottom surface 201 of the handle portion or pulling flap 211 is disposed at an angle al with respect to the base surface 200a or plane 220p (i.e. plane orthogonal to the filter axis) of the end cap 2.
• the angle al is more than 0.5°, or 1°, or 3°, or 4°, or 5°, or 6°, or 7°, or 8°, or 9°, or 10°, or 20°, or 30°.
• the top surface 215 of the handle portion or pulling flap 211 is shown as being generally flat with respect to the base surface 200a or plane 220p (i.e. plane orthogonal to the filter axis) of the end cap 2, but may be provided at an inclination.
• the angle between the top surface 215 and the bottom surface 201 of the handle portion or pulling flap 21 1 al is 0.5°, or 1°, or 3°, or 4°, or 5°, or 6°, or 7°, or 8°, or 9°, or 10°, or 20°, or 30°.
• the end surface 200 of the end cap 2 then describes a ring structure 22.
• the medium 5 and liners 4 and 6 are embedded in the endcap 2.
• the pulling flap or handle portion 211 has an upper surface 215 abutting the end surface 200P and comprises anti slip or improved grip features 212.
• the concave portion 213 in the pulling flap or handle portion 211 provides a widened access opening 202 for a finger to the cavity 214 below the pulling flap or handle portion 211. A user can then for instance grip the pulling flap or handle portion 211 by its lower surface 201 and upper surface 215.
• Fig. 7a and 7b illustrate a further embodiment of the present disclosure. It differs from the previous embodiments in that the first end cap 2 comprises a rigid end cap portion 25, which is bonded to the media pack 5 and possible inner and outer liners (6,4) by means of a glue or other sealing material 26 known to the skilled person.
• a pulling means 21, e.g. pulling flap or handle portion 211 is formed made of an elastically deformable material such as for instance a thermoplastic elastomer, the pulling means being shaped and possibly having further properties as described for any of the previous embodiments.
• the pulling means 21 in the first end cap 2 can comprise a plurality of pulling flaps or handle portions 211, for instance two, three, four or more, arranged at a common supporting base or at independent supporting bases 211 on the first end cap 2, and further having properties as described for the embodiments with a single pulling flap.
• Figs. 8 to 13 include examples of end caps 2 being provided with a plurality of such pulling means 21.
• Fig. 8 shows two pulling means 21 that face each other.
• Fig. 9 shows three pulling means 21 facing each other.
• Fig. 10 shows four pulling means facing each other.
• FIG. 11 shows two pulling means 21, wherein both pulling means 21 are located on the same side of the end cap 2, and thus within a 180 degree angular range of the end cap 2.
• This construction allows the end cap 2 to be more easily removed from a mold (i.e. demolded) as a tilting action can be used to pull the cantilevered portions of the pulling means out of the mold.
• the flaps of the pulling means 21 deflect to a greater degree during demolding as the end cap 2 is pulled generally axially away from the mold.
• Fig. 12 shows two pulling means 21 that face away from each other and from the longitudinal axis of the filter element.
• FIG. 13 shows four pulling means 21 wherein the bases of the pulling means are formed within a common support ring 2a.
• the pulling means 21 shown in Fig. 13 are directed outwardly while still sharing the common support ring 2a. Outwardly facing pulling means 21 can facilitate easier removal of the end cap 2 from the mold.
• Having a plurality of pulling flaps or handle portions 211 may facilitate easy filter removal and may increase the total force that can be applied to the pulling means when removing the filter element from its installed position. It may also improve total grip as pulling may be performed with both hands or a variety of finger positioning combinations.
• Each of the plurality of pulling flaps (and their bases if applicable) can for instance be arranged at regular angular intervals around the longitudinal axis of the filter element. A regular distribution of the pulling tabs may facilitate removal of the filter element during servicing as the user can select the pulling tab or tabs which can more easily be reached and manipulated.
• the single pulling tab or plurality of pulling tabs may be arranged within an angular interval of 180°, or 160°, or 140°, or 120° or 90°, or 45°, for instance at regular angular intervals. This may facilitate a more easy removal of the pulling tabs or handle portions 211 from the production mold as it allows the filter element to be inclined in a direction towards most or all of the plurality of pulling flaps while demolding the first end cap, thereby not only counting on the elastic deformation process of the pulling flaps 211 but also on an unhooking process. [0087] Having a plurality of pulling tabs or handle portions 21 lmay be specifically advantageous for filter elements with a relatively large diameter and weight, for instance main filter elements.
• the filter element can for instance be a main filter element or a safety element in an air intake system for an engine, but the element with the claimed described characteristics can a priori be used in all fields and applications of filtration. It can be used in liquid and gas (e.g. air) filtration. It can be used in the field of gas turbine or industrial filtration filter elements.
• the plurality of pulling flaps or handle portions 211 is formed in a single process, together with the formation of the rest of the end cap 2.
• the plurality of pulling flaps or handle portions 21 1 and the rest of the first end cap material can comprise or consist of an elastically deformable material, such as PU or another suitable material known to the skilled person.

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• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Physics & Mathematics (AREA)
• Geometry (AREA)
• Filtering Of Dispersed Particles In Gases (AREA)

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Citations (5)

• 2017
  • 2017-10-06 DE DE212017000229.8U patent/DE212017000229U1/de active Active
  • 2017-10-06 WO PCT/US2017/055621 patent/WO2018067988A1/en active Application Filing

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