WO2023022721A1

WO2023022721A1 - Filter cartridges; features and methods of assembly; filter assemblies; and, filter cartridge combinations

Info

Publication number: WO2023022721A1
Application number: PCT/US2021/046728
Authority: WO
Inventors: Michael J. Boulos; Steven S. Gieseke; Deepak Ahuja; Vikas Manchanda
Original assignee: Donaldson Company, Inc.
Priority date: 2021-08-19
Filing date: 2021-08-19
Publication date: 2023-02-23

Abstract

Filter cartridge arrangements, features thereof and assembly for use therewith, are provided. Selected filter cartridge features are disclosed. Methods of assembly and systems for use are described. The safety or secondary filter cartridge includes an extension of media, typically surrounding an open filter interior and having a first end and a second end. In general, the open filter interior of the secondary or safety cartridge is large enough to accommodate a primary or main filter cartridge therein. In preferred configurations, the media either: has no pleats; or, if pleated, preferably has no pleats greater than about 3 millimeters in depth, more preferably no greater than 2 mm in depth.

Description

FILTER CARTRIDGES; FEATURES AND METHODS OF ASSEMBLY; FILTER ASSEMBLIES; AND, FILTER CARTRIDGE COMBINATIONS

Field of the Disclosure

The present disclosure relates to filter assemblies, filter cartridges, features and techniques. Certain selected example features and techniques described are configured to be particularly convenient as, or for use with, secondary or safety filter cartridges for air or other gas filter arrangements and assemblies. Also, advantageous main filter cartridges and advantageous filter assemblies are also described that can be used with the secondary or safety cartridges. Preferred features of selected filter cartridges, filter assemblies, and methods of assembly are described.

Background

Gas filters are used in a variety of assemblies and systems. For example, it is desirable to filter intake air to a variety of vehicles and other equipment. Typically, the intake air is combustion air for an internal combustion engine, often a diesel engine. Filtration is generally conducted with a gas (air) cleaner assembly (i.e. a filter assembly) typically including a housing and an internally positioned filter cartridge arrangement. The filter cartridge arrangement typically includes a main filter cartridge, through which the air is passed and which is operated with deposition of particulate material carried therein onto filter media of a main filter cartridge. In a variety of air cleaner assemblies, the main filter cartridge and the remainder of the assembly are configured for out-to-in flow during filtering, in reference to direction of air flow through the media of the main filter cartridge, during normal operation. When this is the case, the media of the main filter cartridge is typically configured surrounding an open filter interior that is a clean air side of the media.

In many instances, a safety or secondary filter cartridge is included within the filter assembly. When a safety or secondary filter cartridge is used with an assembly configured for out-to-in flow during filtering, the safety filter is typically configured with media thereof surrounding an open filter interior and projecting into an open filter (clean gas) interior of the main filter cartridge. Thus, after the gases (air) pass through the media of the main filter cartridge, the gases (air) pass through the media of the safety filter cartridge as those gases (air) are directed toward an outlet from the air cleaner.

In a typical assembly, both the main filter cartridge and the safety filter cartridge are configured as service components. That is, they are configured to be removable from, and to be replaceable within, the air cleaner assembly. As a result, each is typically provided with a releasable housing seal, i.e., a seal which removably seals to a portion of the housing or air cleaner assembly, when the two filter cartridges are properly and operably positioned. Such seals are sometimes referred to as “releasable seals” since they can be established and be removed without damage to the cartridges or housing component(s) engaged.

A variety of assemblies have been developed which can use such general arrangements. Examples are described in WO 2009/014986 Al and WO 2012/116314 Al, each of which is incorporated herein by reference and which are owned by the owner of the present disclosure, Donaldson Co., Inc., of Bloomington Minnesota.

In such air cleaner assemblies, the dirty gas (air) is often introduced through a side, often as a centrifugal inlet, and the clean air exits axially through an end of the air cleaner assembly. In view of this configuration, it is difficult to orient or arrange the air cleaner assembly so that it is oriented in a vertical orientation and also provide that the dirty gas (air) enters through a top end of the air cleaner assembly and clean gas (air) exits through a side of the air cleaner assembly. One reason for this is that such an arrangement requires “reverse flow” compared with the flow arrangement described above. Accordingly, improvements have been sought for providing air cleaner assemblies that provide for “reverse flow” and that also provide for filter cartridges that can configured for “reverse flow” orientation.

Herein, in addition, selected features and filter assemblies, including housings therefor, for advantageous use, assembly, and operation are described. Also, methods are depicted.

Summary

According to the present disclosure, some advantageous features of filter assemblies, such as air cleaner assemblies are provided. Selected advantageous features concern a variety of components for such an assembly. Selected features described and disclosed relate to one or more of: a main filter cartridge; a housing; and, a secondary or safety filter cartridge. There is no specific requirement that all of the advantageous features with respect to all of the components described be implemented, in order to obtain some advantage according to the present disclosure.

According to one aspect of the present disclosure, a filter cartridge, typically to be used as a secondary or safety filter cartridge by being positioned with media thereof oriented around a main filter cartridge, is provided. The safety or secondary filter cartridge comprises an extension of media, typically surrounding an open filter interior and having a first end and a second end. In general, the open filter interior of the secondary or safety cartridge is large enough to accommodate the primary or main filter cartridge therein. In preferred configurations, the media either: has no pleats; or, if pleated, preferably has no pleats greater than about 3 millimeters in depth, more preferably no greater than 2 mm in depth.

Also, herein selected advantageous structural features, for example media support features, for preferred filter cartridges are described. These can be used in association with the various features described previously in this section, or independently, to advantage.

Methods of assembling a filter cartridge in accord with the features described herein are also provided. The methods can be used to advantage, to achieve a desirable filter cartridge in an efficient manner.

Also according to the present disclosure, filter assemblies, including features specifically and advantageously configured for use with preferred filter cartridges are described herein are shown and described. Also main or primary filter cartridge configurations that particularly well adapted for use with components as characterized herein are described. Further, methods of installing main filter cartridges are described

There is no specific requirement that a filter cartridge or component include all of the features specifically characterized herein, or even as specifically characterized above in this section, in order to obtain some benefit according to the present disclosure. Further, there is no specific requirement that the features described herein, in the context of a safety or secondary filter cartridge, only be implemented in a safety filter cartridge, as opposed to an alternate filter cartridge, unless otherwise specifically recited. In addition, while the techniques are described in connection with air filtration, they can be applied with other types of gas filters or in filtering of other media. It is noted, however, that the techniques were particularly developed for, and are particularly advantageous for, air filter applications, especially these involving either or both of: a secondary or safety filter cartridge; and, a central support position in the housing.

Brief Description of the Drawings

Fig. l is a side view of an air cleaner assembly according to the present disclosure.

Fig. 2 is a top view of the air cleaner assembly according to Fig. 1.

Fig. 3 is an alternative side view of the air cleaner assembly according to Fig. 1.

Fig. 4 is an exploded perspective view of the air cleaner assembly according to Fig. 1.

Fig. 4A is an exploded perspective view of the air cleaner assembly according to Fig. 1, but from a different perspective compared to Fig. 4.

Fig. 5 is a sectional view of the air cleaner generally in accord with Fig. 1 taken along line 5-5 in Fig. 2.

Fig. 5A is an isolated sectional view of the access cover for the air cleaner assembly according to Fig. 5.

Fig. 5B is an isolated perspective view of the inside of the housing for the air cleaner assembly according to Fig. 5.

Fig. 5C is a partial perspective, exploded view of the air cleaner assembly according to Fig. 5.

Fig. 6 is a partial sectional view of the primary or main filter cartridge for the air cleaner assembly according to Fig. 5.

Fig. 7 is an exploded view of a portion of the primary or main filter cartridge according to Fig 6.

Fig. 8 is an end view of the primary or main filter cartridge according to Fig. 6.

Fig. 8A is an isolated perspective view of a seal support for the primary or main filter cartridge according to Fig. 8.

Figs. 8B and 8C are alternative exemplary seal designs that can be used on the primary or main filter cartridge. Fig. 9 is a first embodiment of a secondary or safety filter cartridge for use in the air cleaner assembly according to Fig. 1.

Fig. 10 is an end view of the secondary or safety filter cartridge according to Fig. 9.

Fig. 11 is a sectional view of the secondary or safety filter cartridge of Fig. 10 taken along line 11-11.

Fig. 12 is a second embodiment of a secondary or safety filter cartridge for use in the air cleaner assembly according to Fig. 1.

Fig. 13 is an end view of the secondary or safety filter cartridge according to Fig. 12.

Fig. 14 is a sectional view of the secondary or safety filter cartridge according to Fig. 13.

Fig. 15 is an exploded view of a portion of the secondary or safety filter cartridge according to Fig. 14.

Detailed Description

I. An Improved Filter Assembly and Secondary or Safety Filter Cartridge Generally

As indicated previously, in general, portions of the present disclosure relate to features and techniques that are specifically adapted for advantageous use in secondary or safety filter cartridge arrangements and assemblies; although the techniques can be applied in other applications. The techniques are understandable, for example, in the context of use in an air cleaner assembly that is characterized as “reverse flow” which means reverse from those depicted in, for example, WO 2009/014986A1 and WO 2012/116314 Al.

In general, such reverse flow air cleaner assemblies comprise an air cleaner housing, a primary or main filter cartridge, and a secondary or safety filter cartridge. The main filter cartridge typically comprises media surrounding an open filter interior. The assembly is typically configured for “in-to-ouf ’ flow during filtering, with respect to gas (air) flow direction through the media of the main filter cartridge. By the term “in-to-ouf ’ flow in this context, it is meant that the flow during filtering through the media of the main filter cartridge is generally: from an open filter interior of the main filter cartridge surrounded by media, through the main cartridge media, to an exterior of the main cartridge. Thus, the open filter interior of the main filter cartridge is a dirty air region.

The main filter cartridge is positioned to be loaded with contaminant thereon during use, and is, as a result, typically constructed as a serviceable component. Thus, the housing is typically configured with a main housing body or base section and an access cover; the access cover comprising a serviceable cover removable for internal servicing. The main filter cartridge is typically configured to be removably installed within the housing interior. To accomplish this, the main filter cartridge has a releasable housing seal. By “releasable,” in this context, it is meant that the seal is established by the main cartridge engaging a selected portion of the housing (or assembly) when the cartridge is installed, and the seal is readily removed and released when the cartridge is removed from the housing. Such “releasable” seals are capable of being separated or removed without damage to either the main filter cartridge or the housing.

Many features concerning main filter cartridge configuration, relate to: ensuring a desirable amount of filter media surface area available for load, given limitations on volume, etc.; ensuring that the housing seal is configured so that the seal is properly established and maintained; and, ensuring that the cartridge cannot be misinstalled and/or that an alternate, inappropriate, cartridge cannot be inadvertently installed in the system. A variety of constructions have been developed to address these issues, including the general ones described in WO 2009/014986 Al and/or WO 2012/116314 Al.

A housing, for example of a reverse flow air cleaner assembly, is typically provided with an inlet air (gas) conduit or tube, in communication with open interior of the main filter cartridge. Thus, the housing seal on the main filter cartridge is typically either sealed to the inlet flow tube, or to a portion of the housing that surrounds a volume with which the inlet flow conduit or tube communicates. Herein, the portion of the air cleaner assembly to which the seal of the main cartridge releaseably engages, will be referred to as a portion of the housing, whether it is an inlet separable from a remainder of the housing structure, or some structure integral with other portions of the housing structure. In many systems, it is desirable to provide the air cleaner assembly with a serviceable safety or secondary filter cartridge. The safety or secondary cartridge is typically positioned in the air (gas) flow path between the main filter cartridge, and the outlet flow exit of filtered air (gas) from the filter assembly (housing). When the main filter cartridge is configured for “in-to-out flow” during filtering, this means that the safety or secondary cartridge is typically positioned with at least a portion thereof oriented around the main filter cartridge.

Herein, the terms “secondary” or “safety,” when used in reference to a filter cartridge positioned with media downstream of the main filter cartridge, are meant to be used interchangeably and without differentiated meaning.

Preferably, the safety filter cartridge is an optional serviceable component independent of the main filter cartridge. This means: that the main filter cartridge can be installed in, and be removed from, the housing, without removing (and preferably without dislodging from proper mounting) the optional safety cartridge; and, that servicing the main filter cartridge does not necessarily require servicing the optional safety filter cartridge.

Independent main and safety cartridges are advantageous for a number of reasons. An advantage, is that when the main cartridge is serviced, the safety cartridge can be left in place so as to avoid dirt and dust from entering the clean gas (air) plenum of the gas (air) cleaner system, for example as an interior of the housing is cleaned. Other advantages relate to convenience of installation and assembly, as well as convenience of component manufacture. In addition, separate construction allows for efficient material usage and disposition, especially since the main filter cartridge may need to be serviced, or be removed for inspection, more often than the safety cartridge.

There are a number of issues relating to safety or secondary filter cartridge configuration and assembly. For example, in many air cleaner assemblies, there is little option available for location of sealing between the housing and the safety filter cartridge. One region sometimes available, is an interior (or exterior) of a flange or tubular surface that surrounds a gas inlet flow from the housing. This could, for example, comprise a surface of an inlet flow tube, or it could comprise a surface of a flange that projects into the housing at a location surrounding, but spaced from, the inlet flow tube. When a cartridge seals to such a flange or tube, the seal is sometimes referenced as “radially” directed. By this, it is meant that the seal forces are generally directed around a central axis, with the forces of sealing being generally directed toward or away from that central axis. In the present disclosure, the central axis referenced, is an axis through an air flow inlet from the associated cartridge, and the central axis is also surrounded by the media. A seal may be referred to as “radially outwardly directed” and by similar terms, if the seal engages a housing component that surrounds the seal during use; and, the seal may be generally characterized as “radially inwardly directed” or by similar terms, when the seal is configured to surround and engage the housing component in use. It should be understood that the housing component referenced is the housing component against which the seal member forms a seal, in use.

An issue with radially directed seals, is that they can take-up radial dimension within the housing. This reduces the cross-sectional area available for gas flow entering the cartridge and/or housing, and can undesirably add to restriction. By orienting the safety around the main filter cartridge, it is possible to maximize the inlet flow cross-sectional area relative to the size of the main filter cartridge inlet. That is, there is no need for a safety located within the main filter cartridge interior when the air cleaner is designed for reverse flow.

Of course, the housing in which the safety cartridge is used can be made sufficiently large to minimize this problem, but there are limitations imposed on this by: a preference for the main filter cartridge to have as much surface area and media volume as reasonably possible; a preference that the air cleaner be as small and light as reasonably possible; cost and material issues; and, issues with handling and shipping components.

The restriction issue presented by reduction in cross-sectional area defined by the safety cartridge for air flow, as characterized in this section, relates to the dimension of radial direction (width) of the secondary or safety filter cartridge toward a central axis, from the seal surface, i.e. the part of the radial seal positioned to sealingly engage the housing. In general, it is desired that this amount of radial width or extension of the safety cartridge structure be maintained as small as reasonably possible, so as to ensure that the inlet flow cross-sectional size, through an end of the safety filter cartridge remains as large as reasonably possible. In general terms, the surface area of media available in the filter cartridge is preferably as large as reasonable for the volume available. This renders advantageous media face velocities. Media face velocity is generally the gas flow rate through the media divided by upstream surface area of the media. Smaller media surfaces lead to higher face velocities. Higher face velocities are typically less desirable than lower face velocities for a number of reasons. For example, higher face velocities generally result in a greater restriction placed on air flow through the air cleaner assembly, which is undesirable with respect to equipment operation and filter lifetime. Also, the higher the face velocity, the more likely a particle can penetrate through the media and reach the clean air (gas) plenum. By providing the secondary filter cartridge around the primary filter cartridge, the volume of the media available for filtration in the secondary filter cartridge can be increased thereby lowering face velocities.

It can be understood that non-pleated media of a given outer perimeter size has a higher face velocity than pleated media which defines the same outer perimeter size (i.e., outer perimeter size disregarding pleat presence). However, introduction of pleats into the media has generally been undesired for certain secondary filters, as pleats introduce radial width dimension to the cartridge, which leads to increase in restriction to gas flow outwardly from the cartridge and assembly. Herein in the next section, selected filter cartridge features are described, which can be applied to balance these issues to advantage.

A. An Example Filter Assembly and General Features, Figs. 1-5C

In Figs. 1-5B, a filter assembly (for example an air cleaner) having advantageous features and using a primary or main filter cartridge and a secondary or safety cartridge is depicted.

Attention is first directed to Figs. 1-3. In Figs. 1-3, a gas filter assembly 100 configured as an air cleaner assembly is depicted. The filter assembly 100 comprises a housing 101 having, operably positioned therein, a main or primary filter cartridge and a secondary or safety cartridge therein. In general, air to be filtered flows into housing 101 through gas (air) flow inlet arrangement 105. The air is directed through primary or main cartridge, with “in-to-ouf ’ flow (also referred to as “reverse flow”) and then through a secondary filter, with an “in-to-ouf ’ flow. The filtered gas (air) exits housing 101 through gas flow outlet arrangement 106. The gas flowing into the air filter assembly can be considered axial flow because it flows in an axial direction through the gas flow inlet 105, and clean-air flowing out the outlet flow arrangement 106 can be considered as radial flow because it flows in a radial direction away from the central axis extending through the gas filter assembly 100 and also through the gas flow inlet 105. Also depicted is an access cover 108 that is attached to the housing 101 by over center latches 110. Various other arrangements for attaching the access cover 108 to the housing 101 can be provided. The housing 101 includes a mounting pad 112 for securing the filter assembly 100 in place on a vehicle, for example.

An advantage of the filter assembly 100 is that it can be arranged in a vertical orientation as depicted in Fig. 1, such as when mounted on a vehicle. Dirty air flowing axially through the gas flow inlet 105 can be pre-cleaned prior to entry into the filter assembly 100, if desired, and any moisture in the incoming air stream may fall out of the air and collect in the access cover 108. Water collecting in the access cover 108 can be permitted to drain via gravity through a valve 115 in the access cover 108. The valve 115 can be an umbrella valve that maintains a seal when the inside of the filter assembly 100 is under vacuum. Once flow within the filter assembly decreases to a certain level, the pressure within the filter assembly 100 permits the water to drain out from the access cover 108 via gravity.

By vertically orienting the filter assembly 100, the filter assembly 100 can be serviced from the bottom through the access cover 108. That is, the access cover 108 can be removed from the housing 101 and the primary filter cartridge, and even the secondary filter cartridge, can be removed from the housing 101. In general, it is desirable to service the filter assembly 100 by removing the primary filter cartridge while leaving the secondary filter cartridge in place. An advantage of the interaction between the housing 101 and the secondary filter cartridge, as described below, is that the seal member on the secondary filter cartridge can engage with the housing 101 in such a way that it remains attached to the housing 101 even while removing the primary filter cartridge.

Another advantage of a vertical orientation for the filter assembly 100 is that any particulates in the dirty air region inside the filter assembly 100 can simply fallout of the filter assembly 100 when the access cover 108 is removed. This is advantageous compared with other filter assembly designs where removing a primary filter cartridge can result in particulate being dislodged and falling into a clean air intake. Furthermore, servicing the filter assembly 100 through the bottom of the housing 101 is convenient because it is generally easier to remove a relatively heavy and bulky primary filter cartridge through a bottom opening rather than a top or side opening. In other words, gravity can assist with removing a filter cartridge through a bottom opening.

Now referring to Figs. 4 and 4A, the filter assembly 100 is shown in an exploded configuration with a primary or main filter cartridge 120 and a secondary or safety filter cartridge 130. Also illustrated are the housing 101, the access cover 108, and the valve 115 that attaches to the access cover 108. As illustrated, the secondary filter cartridge 130 is configured to be arranged around the primary filter cartridge 120 when installed in the filter assembly 100.

The secondary filter cartridge 130 includes filter media 132 extending from a first media end 134 to a second media end 136. A first seal member 138 is provided at the first media end 134, and a second seal member 140 is provided at the second media end 136. The second seal member 140 is configured to be pinched between the lip 109 on the access cover 108 and the corresponding lip 102 on the housing 101, and thereby forming an axially directed seal. The first seal member 138 is configured to form a radially directed seal inside the housing 101. In addition, the secondary filter cartridge 130 includes a first open end cap 142 that includes the first seal member 138, and a second open end cap 144 that includes the second seal member 140. The first open end cap 142 includes a first end cap aperture 141 therethrough, and the second open end cap 144 includes a second end cap aperture 143 therethrough. The apertures 141 and 143 can be referred to as central apertures.

The primary filter cartridge 120 includes an extension of media 122, which is preferably cylindrical or conical pleaded media, extending from a first media end 124 to a second media end 126. A first seal member 128 is located at the first media end 124 and a second seal member 129 is located at the second media end 126. Both the first and second seal members 128 and 129 are configured to provide a radially directed seal inside the housing 101 and the access cover 108, respectively. In addition, the primary filter cartridge 120 includes a first open end cap 146 that includes the first seal member 128, and a second open end cap 148 that includes the second seal member 129. The first open end cap 146 includes a first end cap aperture 145 therethrough, and the second open end cap 148 includes a second end cap aperture 147 therethrough. The apertures 145 and 147 can be referred to as central apertures. The first and second open end caps 146 and 148 permit dirty air or unclean air (gas) to flow into the interior volume 156 via the gas flow inlet arrangement 105 and through the inlet flange 154 and the first open end cap 146, and water is permitted to flow through the second open end cap 148 and collect at the bottom of the access cover 108 where it is eventually released via the valve 115. Of course, the second open end cap 148 can be replaced with a closed end cap if removal of water therefrom is not necessary.

Now referring to Figures 5-5C, the inside 108i of the access cover 108, the inside lOli of the housing 101, and the interaction of the primary or main filter cartridge 120 and the secondary or safety filter cartridge 130 with the access cover 108 and the housing 101 are illustrated.

The access cover 108 includes an axially extending flange 150 and a second flange 152. The axially extending flange 150 includes an outside surface 150o that forms a seal with the second seal member 129 of the primary filter cartridge 120 to form a radially directed seal. In this case, the seal can be characterized as an internally directed radial seal. The second flange 152 extends around the primary filter cartridge 120 when the primary filter cartridge 120 is installed in the assembly 100. The axially extending flange 150 and the second flange 152 can be provided as extending continuously around an axis extending through the air cleaner 100 and including the dirty air inlet 105.

The housing 101 includes an axially extending flange 160 having a having an inner surface 160i. The first seal member 128 of the primary filter cartridge 120 engages the inner surface 160i of the axially extending flange 160 of the housing 101. The axially extending flange 160 can be referred to a radial seal flange since the first seal member 128 engages the inner surface 160i of the radial seal flange 160 to form a radially directed seal. This seal arrangement can be referred to as an externally directed radial seal since the seal forces are directed radially outwardly against the radial seal flange 160. Also shown is an inlet flange 154. Dirty or unclean air flows into the interior 156 of the primary filter cartridge 120 via the inlet 105 and the inlet flange 154. The inlet flange 154 includes gaps or recesses 155 for receipt of projections 157 projecting inwardly from the first open end cap 146. The projections 157 are able to index with the recesses 155 to help guide proper engagement between the primary filter cartridge 120 and the housing 101. The housing also includes an axially extending flange 166 having an inner surface 166i. The first seal member 138 of the secondary cartridge 130 engages the inner surface 166i to form a radially directed seal. The radially directed seal can be referred to as an outwardly directed radial seal because the sealing forces are directed radially outwardly toward the inner surface 166i.

The secondary filter cartridge 130 is illustrated having a second seal member 140 pinched between the housing 101 and the access cover 108, and a first seal member 138 radially sealed to a radial seal flange 160 on the housing 101. As illustrated, the first seal member 138 form a radial seal with the radial seal flange 160, and the radial seal can be referred to as an outwardly directed radial seal since the forces are directed outwardly from a central axis toward the radial seal flange 160.

B. An Example Primary Filter Cartridge, Figs. 6-8A

Now referring to Figs. 6-8A, the primary filter cartridge 120 which can be used in the filter assembly 100 is illustrated. The primary filter cartridge 120 is illustrated having a first end 170 and a second end 172. The first end 170 includes a first end piece 171 and can be characterized as having an open end 174 with a central aperture 176. The second end 172 includes a second end piece 173 and can be characterized as having an open end 178 and a central aperture 180. The first end piece 171 includes a first housing seal arrangement 181 which includes a seal material and is constructed to form and outwardly directed radial seal. The second end piece 173 includes second housing seal arrangement 183 that includes a seal material and is constructed to form an internally directed radial seal. The filter media 182 can be provided as cylindrical pleaded media or conical pleated media extending between the first end 170 and the second end 172. In addition, the media 182 can be supported by an inner liner 184 and an outer liner 188. In addition, the seal member 174 includes therein a seal support 190.

The first seal member 174 can be provided with a variety of seal arrangements including the seal arrangements depicted in International Publication Nos. WO 2013/063497 WO 2017/139673, both being assigned to Donaldson Company, Inc., and the entire disclosures of which are incorporated herein by reference.

Herein, the exemplary described seal arrangement generally relates to arrangements in which the media of the cartridge surrounds an open filter interior, and unfiltered air flows through an open end piece on an open end of the media pack and into an open interior, and then during filtering flow goes through this media from the open interior.

Referring to Figures 5C-8A, the primary filter cartridge 120 is depicted having filter media 182 and a first end piece 171 at a first end of the cartridge 170. The first end piece 171 depicted includes a molded-in-place portion 200 configured to have a seal member 202 generally in the form of a radial seal 202 (in the example a radially outwardly directed seal) comprising a plurality of outwardly curved (convex) portions or regions 204 spaced by, preferably, non-straight, inwardly directed, preferably outwardly facing, (concave) portions or regions 206. The shape of the outwardly curved (convex) portions or regions 204 can be referred to as projections or more particularly as lobes although a lobe shape is not required. The number of outwardly curved portions 204 shown is six, and they are separated by six inwardly directed portions 206. The number of outwardly curved portions 204 can be at least about 2 and preferably from about 2 to about 20, and more preferably about 3 to about 8. The number of inwardly directed portions 206 can be at least one, preferably about 2 to about 20, and more preferably about 3 to about 8.

Furthermore, the molded-in-place portion 200 can be molded over a structural support, such as the seal support 190, to support the seal member 202. The seal support 190 includes a flange member 210 that supports the seal member 202 when in a radially directed seal with the housing. The flange member 210 is provided with outwardly directed, preferably curved, portion 214 alternating with inwardly directed, and preferably curved, portions 216 that correspond to the outwardly directed portions 204 and the inwardly directed portion 206 of the seal member 202. The number and shape of the outwardly directed portions 214 and the inwardly directed portions 216 can correspond to that discussed above for the outwardly directed portions 204 and the inwardly directed portions 206. A support structure 190, as indicated above, can be included embedded within molded-in-place portion 200 and would thus be out of view of the embodiment shown in Fig. 5C except for the projections 157. As illustrated, the projections 157 extend from an inner support 220 that is attached to the seal support 190 by a plurality of extensions 222. It is pointed out that the inner support 220 can be provided having a circular shape while the seal support 190 can be provided with a non-circular shape. The extensions 222 can provided as an alternative arrangement that secures the inner support 220 and the seal support 190 in place relative to each other.

As an alternative, a wavy wall seal member surface 295 can be provided as an outwardly facing radial seal or as an inwardly facing radial seal. In the embodiment shown in Fig. 8B, the wavy wall seal member surface 295 is depicted as an outwardly facing radial seal. Fig. 8B shows an embodiment of an outwardly directed wavy wall seal member surface 295 with a plurality of radially outwardly projecting and axially extending sections 298 alternating with radially inwardly projecting and axially extending sections 299. The embodiment depicted in Fig. 8C includes an inwardly directed wavy wall seal member surface 295' with a plurality of radially outwardly projecting and axially extending sections 298' alternating with radially inwardly projecting and axially extending sections 299'. Also shown is the central open volume 215i.

The “wavy wall seal member surface” is characterized as having the outwardly projecting and inwardly projecting sections as extending axially. Because these sections extend axially, it is possible to move the seal members axially (in the direction along a central axis) into and out of the housing seal surface to thereby create the radial seal. In addition, because the outwardly projecting and inwardly projecting sections extend axially, the filter element resists rotation about the central axis when installed (e.g., when a radial seal is created). The seal surface is configured to interact with a complementary “wavy wall seal housing surface” having outwardly projecting and inwardly projecting sections that extend axially. As shown in Figs. 8B and 8C, in some embodiments the wavy wall seal member surface 295 and 295’ can be provided as part of a seal member that is supported by a non-wavy wall support 292 and 292’. The non- wavy wall support 292 and 292’ can be provided as a preformed part that forms the open end cap such as that shown, for example, in Fig. 8A except that the seal support is shaped differently. Alternatively, the non-wavy wall support 292 and 292’ can be provided as, for example, the inner liner 184 or the outer liner 188. In some embodiments, the seal member may not include a support (e.g., such as in embodiments where the seal member extends beyond an axial end of the media and/or support structure and does not include a separate component such as a plastic preform). The non-wavy wall support can be used to support the wavy wall seal member surface when the wavy wall seal member surface is provided as an outwardly directed radial seal and when provided as an inwardly directed radial seal. In some embodiments, the shape of the wall support is different than the shape of the seal member surface. In such embodiments, a thickness T of the seal between the seal surface and the wall support can vary around the perimeter (e.g., in a radial direction), either continuously or intermittently. In certain embodiments, the thickness T of the seal between the seal surface and the wall support vary around at least a portion of the perimeter in a regularly repeating pattern. In some embodiments, a ratio of a maximum thickness Tma to a minimum thickness Tme is greater than 1.1, such as greater than about 1.2 (e.g., greater than about 1.3). In certain embodiments, T_me is at least about 1 mm, such as at least about 2 mm (e.g., at least about 4 mm).

The seal member 294 can include a plurality of the outwardly projecting and axially extending sections 298 and/or (e.g., alternating with) a plurality of inwardly projecting and axially extending sections 299. The resulting seal surface can be referred to as a wavy wall seal member surface 295. In general, a perimeter of the outwardly directed seal surface 294s of the seal member 94 includes at least about 20 radially outwardly projecting and axially extending sections 98 alternating with corresponding inwardly projecting and axially extending sections 99. The number can vary, but is generally expected that a perimeter will include about 20 to about 400 (e.g., about 20 to about 120, such as about 20 to about 40) radially outwardly projecting and axially extending sections alternating with inwardly projecting and axially extending sections. In some embodiments, the radially directed seal surface comprises less than about 13 of the radially outwardly projecting and axially extending portions alternating with less than about 13 of the radially inwardly projecting and axially extending portions along a distance of one inch along the seal support extending around the filter cartridge axis. The wavy wall seal member surface 295 can be characterized in terms of “pitch” which is the distance from peak to adjacent peak. In the case of the wavy wall seal member surface 295, the pitch can be defined as the distance from the peak 298 to the adjacent peak 298. Alternatively, the pitch can be defined as the distance between the adjacent troughs 299 and 299. As described previously, the wavy wall seal member surface 295 can include a plurality of radially outwardly projecting and axially extending sections 298 alternating with a plurality of radially inwardly projecting and axially extending sections 299. The radially outwardly projecting and axially extending sections 298 form peaks 298p and the radially inwardly projecting and axially extending sections 299 form troughs 299t. The wavy wall seal member surface 295 can be characterized as having a pitch that allows the service provider (installer of the filter element) with a degree of indexing that allows the service provider to correctly index the filter element within the housing without having to re-grip the filter element. That is, the filter element can be correctly indexed by only rotating the filter element within a range of about plus or minus 15 degrees (preferably plus or minus 10 degrees) from zero or neutral. In order to achieve this, the pitch can be at least 1 mm/lobe, such as at least 2 mm/lobe, or, in some embodiments, at least 4 mm/lobe. In certain embodiments, the pitch can be less than 25 mm/lobe, such as less than 12 mm/lobe, less than 10 mm/lobe, or less than 8 mm/lobe. In some embodiments, the pitch of the lobes is relatively constant. In other embodiments, the pitch varies between lobes or groups of lobes.

C. An Example Secondary Filter Cartridges, Figs. 9-15

The secondary or safety filter cartridge 130, Figs. 9-11, generally depicts an example filter cartridge in accord with selected, optional, improvement according to the present disclosure. The example filter cartridge 130 depicted, is configured with features advantageous for use in a safety or secondary filter cartridge, for example to be used in an assembly configured for in-to-out flow through a main filter cartridge during operation; and, in which the secondary filter cartridge is configured to be sealed radially to a surface of a housing component tube or (flange), and to a surface of a housing between the housing and an access cover as an axial pinch seal, and with media of the safety filter cartridge extending around the main cartridge. It will be understood that the selected advantageous features described herein, however, can be applied in a variety of alternate applications/configurations.

The filter cartridge 130 depicted comprises an extension 132e of media 132 extending between first and second media ends 134, 136. In general terms, the media 132 surrounds a central axis X and defines an open interior 132i, which is sized to receive a main filter cartridge therein. The filter cartridge 130 includes an inside liner 240 and an outside liner 242. The inside liner 240 and the outside liner 242 support and hold the filter media 132 in place, and provide support for the first seal member 138 and the second seal member 140. As illustrated in Fig. 11, the inside liner 240 and the outside liner 242 form a support 244 for the first seal member 138 and a support 246 for the second seal member 140. In addition, the first seal member 138 is shown molded over the support 244, and the second seal member 140 is shown molded over the support 246. As an alternative to that shown, the first seal member 138 can be separately formed and attached to the support 244 and the second seal member 140 can be separately formed and attached to the support 246. In addition, the inside support 240 and the outside support 242 can be formed by molding over the media 132 and also forming the supports 244 and 246. Alternatives are possible. For example, the first seal member 138 and the second seal member 140 can be provided without a support structure therein, or can be provided with a support structure that is neither part of the inside liner 240 nor the outside liner 242, or can be provided with a support structure that is one of the inside liner 240 or the outside liner 242.

The second seal number 140 is illustrated as a radially extending flange 141. The radially extending flange 141 is provided as extending radially outwardly from the secondary filter cartridge 130, and includes first and second surfaces 143, 145 that are intended to be pinched between the housing 101 and the access cover 108. Accordingly, the first and second surfaces 143, 145 can be provided as seal surfaces.

Now referring to Figs. 12-15 depicting an alternative secondary filter cartridge 300. The secondary filter cartridge 300 includes filter media 302, a first and 304 and a second end 306. Also included are inside support 310 and outside support 312. The inside support 310 and the outside support 312 form the first seal member support 314 and the second seal member support 316. In addition, the inner support 310 and the outer support 312 hold the media 302 in place. Furthermore, the secondary filter cartridge 300 includes an interior space 302i that is configured to receive therein the primary filter cartridge.

The secondary filter cartridge 300 includes a first seal member 320 and a second seal member 322. The first seal member 320 can be provided as an o-ring 324 that fits within a groove 326 formed by the first seal member support 314 and the second seal member support 315. The second seal number 322 is supported by the second seal member support 316.

Both the secondary filter cartridge 130 and the secondary filter cartridge 300 are illustrated showing conically arranged media 132 and 302. It should be appreciated that the media 132 and 302 can, alternatively, be arranged cylindrically. A conical arrangement is desired where the diameter is greater at the second end 136 and 306 than at the first end 134 and 304. This can be provided for advantage when servicing the filter assembly by removing the primary filter cartridge from inside the secondary filter cartridge 130 and 300 through the second end 136 and 306. Accordingly, it may be advantageous to have a little bit of room to rock the primary filter cartridge out of a sealing relationship with the housing 101. A larger diameter at the second end 136 and 306 more easily permits rocking of the primary filter cartridge and removal from the housing 101.

It should also be appreciated that the secondary filter cartridge 130 and 300 can remain in place in the housing 101 as a result of the seal between the first seal members 138 and 320 and the housing 101 when servicing the filter assembly 100 by replacing the primary filter cartridge 120. This can be provided as a result of the first seal members 138 and 320 engaging radial seal flange 160 on the housing 101 (see Fig. 5) sufficiently so that the secondary filter cartridge 130 or 300 remains in place when removing and replacing the primary filter cartridge 120 when the access cover 108 is removed.

D. Selected General Characterizations and Aspects

According to the present disclosure, filter assemblies, components and features thereof are described. There is no specific requirement that an assembly, component or feature include all of the specific detail characterized herein, in order to obtain some benefit according to the present disclosure. The following is a list of general characteristics and features of an air filter cartridge that can be characterized as a safety or secondary filter cartridge, and general characteristics and features of an air cleaner assembly that includes the safety or secondary filter cartridge.

An air filter cartridge for removable installation in an air cleaner housing; the air filter cartridge including: (a) media surrounding and defining an open interior; (i) the media extending between first and second ends; (b) a first end piece at the first end of the media; (i) the first end piece having a central air flow aperture therethrough, in communication with the open filter interior; (c) a first housing seal arrangement on the first end piece, wherein the first housing seal arrangement is constructed to form a radially directed seal, in use; (d) a second end piece at the second end of the media; (i) the second end piece having a central aperture therethrough, in communication with the open filter interior; (e) a second housing seal arrangement on the second end piece, wherein the second housing seal arrangement is constructed to form a seal, in use.

The air filter cartridge can be provided so that: the second housing seal is an axially directed pinch seal; the second housing seal is a radially directed seal; the first end piece is molded-in-place; the first housing seal arrangement is molded integral with the first end piece; the media is non-pleated; the media is pleated; the media has an outer perimeter increasing in cross-sectional size in extension from the first end to the second end; the cartridge includes an inner liner surrounded by the media; the cartridge includes an outer liner around the media; and/or the inner liner and the outer liner form a seal support for the first housing seal arrangement and form a seal support for the second housing seal arrangement.

An air filter assembly including: (a) a housing defining: an interior; an air flow inlet, an axially extending main filter cartridge sealing flange, an axially extending safety filter cartridge sealing flange located radially outside of the safety filter cartridge sealing flange, a housing lip, and an air flow outlet; (b) an access cover having an axially extending main filter cartridge sealing flange, and an access cover lip that corresponds to the housing lip; (c) a safety filter cartridge operably and removably positioned within the housing interior, the safety filter cartridge comprising: (i) media surrounding and defining an open interior; (A) the media extending between first and second ends; (ii) a first end piece at the first end of the media; (A) the first end piece having a central air flow aperture therethrough, in communication with the open filter interior; (iii) a first housing seal arrangement on the first end piece, wherein the first housing seal arrangement forms a radially directed seal with the housing axially extending safety filter cartridge sealing flange; (iv) a second end piece at the second end of the media; (A) the second end piece having a central aperture therethrough, in communication with the open filter interior; (v) a second housing seal arrangement on the second end piece, wherein the second housing seal arrangement is constructed to form an axial seal pinched between the housing lip and the access cover lip.

The air filter assembly can be provided so that: the first end piece is molded-in- place; the first housing seal arrangement is molded integral with the first end piece; the media is non-pleated; the media is pleated; the media has an outer perimeter increasing in cross-sectional size in extension from the first end to the second end; (a) the cartridge includes a central liner surrounded by the media; (a) the cartridge includes an outer liner around the media; the inner liner and the outer liner form a seal support for the first housing seal arrangement and form a seal support for the second housing seal arrangement; (a) a main filter cartridge positioned in the housing interior and within the safety filter cartridge open interior, wherein the main filter cartridge comprising: (i) main filter cartridge media surrounding and defining a main filter cartridge filter open interior; (A) the main filter cartridge media extending between first and second ends; (ii) a first end piece at the first end of the main filter cartridge media; (A) the first end piece having a central air flow aperture therethrough, in communication with the main filter cartridge open filter interior; (iii) a main filter cartridge first housing seal arrangement on the main filter cartridge first end piece, wherein the main filter cartridge first housing seal arrangement forms a radially directed seal with the housing axially extending main filter cartridge sealing flange; (iv) a second end piece at the second end of the main filter cartridge media; (A) the second end piece having a central aperture therethrough, in communication with the main filter cartridge open filter interior; (v) a main filter cartridge second housing seal arrangement on the second end piece, wherein the main filter cartridge second housing seal arrangement form a radially directed seal with the axially extending main filter cartridge sealing flange; the main filter cartridge first housing seal arrangement forms an outwardly directed radial seal; the main filter cartridge first housing seal arrangement comprises a non-circular seal; the non-circular seal comprises alternating outwardly curved portions and inwardly directed portions; the access cover comprises a valve releasing water form inside the air filter assembly; and/or the air filter assembly is constructed for vertical orientation when used on a vehicle so that the access cover is located on a bottom of the air filter assembly, and servicing of the air filter assembly is through a bottom opening when the access cover is removed.

Also described is a vehicle that includes an air cleaner assembly provided in a vertical orientation so that the access cover is located on a bottom of the air filter assembly, and servicing of the air filter assembly is through a bottom opening when the access cover is removed.

The principles, techniques, and features described herein can be applied in a variety of systems, and there is no requirement that all of the advantageous features identified be incorporated in an assembly, system or component to obtain some benefit according to the present disclosure. In addition, the dimensions characterizing an example system are meant to indicate a usable construction, and variations from them are possible.

Claims

What is claimed is:

1. An air filter cartridge for removable installation in an air cleaner housing; the air filter cartridge comprising:

(a) media surrounding and defining an open interior;

(i) the media extending between first and second ends;

(b) a first end piece at the first end of the media;

(i) the first end piece having a central air flow aperture therethrough, in communication with the open filter interior;

(c) a first housing seal arrangement on the first end piece, wherein the first housing seal arrangement is constructed to form a radially directed seal, in use;

(d) a second end piece at the second end of the media;

(i) the second end piece having a central aperture therethrough, in communication with the open filter interior;

(e) a second housing seal arrangement on the second end piece, wherein the second housing seal arrangement is constructed to form a seal, in use.

2. An air filter cartridge according to claim 1 wherein:

(a) the second housing seal is an axially directed pinch seal.

3. An air filter cartridge according to claim 1 wherein:

(a) the second housing seal is a radially directed seal.

4. An air filter cartridge according to claim 1 wherein:

(a) the first end piece is molded-in-place.

5. An air filter cartridge according to claim 1 wherein:

(a) the first housing seal arrangement is molded integral with the first end piece.

6. An air filter cartridge according to claim 1 wherein:

(a) the media is non-pleated.

23 n air filter cartridge according to claim 1 wherein:

(a) the media is pleated. n air filter cartridge according to claim 1 wherein:

(a) the media has an outer perimeter increasing in cross-sectional size in extension from the first end to the second end. n air filter cartridge according to claim 1 wherein:

(a) the cartridge includes an inner liner surrounded by the media. n air filter cartridge according to claim 9 wherein:

(a) the cartridge includes an outer liner around the media. n air filter cartridge according to claim 10 wherein:

(a) the inner liner and the outer liner form a seal support for the first housing seal arrangement and form a seal support for the second housing seal arrangement. n air filter assembly comprising:

(a) a housing defining: an interior; an air flow inlet, an axially extending main filter cartridge sealing flange, an axially extending safety filter cartridge sealing flange located radially outside of the safety filter cartridge sealing flange, a housing lip, and an air flow outlet;

(b) an access cover having an axially extending main filter cartridge sealing flange, and an access cover lip that corresponds to the housing lip;

(c) a safety filter cartridge operably and removably positioned within the housing interior, the safety filter cartridge comprising:

(i) media surrounding and defining an open interior;

(A) the media extending between first and second ends;

(ii) a first end piece at the first end of the media; (A) the first end piece having a central air flow aperture therethrough, in communication with the open filter interior;

(iii) a first housing seal arrangement on the first end piece, wherein the first housing seal arrangement forms a radially directed seal with the housing axially extending safety filter cartridge sealing flange;

(iv) a second end piece at the second end of the media;

(A) the second end piece having a central aperture therethrough, in communication with the open filter interior;

(v) a second housing seal arrangement on the second end piece, wherein the second housing seal arrangement is constructed to form an axial seal pinched between the housing lip and the access cover lip; and An air filter assembly according to claim 12 wherein:

(a) the first end piece is molded-in-place. An air filter assembly according to claim 12 wherein:

(a) the first housing seal arrangement is molded integral with the first end piece. An air filter assembly according to claim 12 wherein:

(a) the media is non-pleated. An air filter assembly according to claim 12 wherein:

(a) the media is pleated. An air filter assembly according to claim 12 wherein:

(a) the media has an outer perimeter increasing in cross-sectional size in extension from the first end to the second end. n air filter assembly according to claim 12 wherein:

(a) the cartridge includes an inner liner surrounded by the media. n air filter assembly according to claim 18 wherein:

(a) the cartridge includes an outer liner around the media. n air filter assembly according to claim 19 wherein:

(a) the inner liner and the outer liner form a seal support for the first housing seal arrangement and form a seal support for the second housing seal arrangement. n air filter assembly according to claim 12 further comprising:

(a) a main filter cartridge positioned in the housing interior and within the safety filter cartridge open interior, wherein the main filter cartridge comprising:

(i) main filter cartridge media surrounding and defining a main filter cartridge filter open interior;

(A) the main filter cartridge media extending between first and second ends;

(ii) a first end piece at the first end of the main filter cartridge media;

(A) the first end piece having a central air flow aperture therethrough, in communication with the main filter cartridge open filter interior;

(iii) a main filter cartridge first housing seal arrangement on the main filter cartridge first end piece, wherein the main filter cartridge first housing seal arrangement forms a radially directed seal with the housing axially extending main filter cartridge sealing flange;

(iv) a second end piece at the second end of the main filter cartridge media;

(A) the second end piece having a central aperture therethrough, in communication with the main filter cartridge open filter interior;

26 (v) a main filter cartridge second housing seal arrangement on the second end piece, wherein the main filter cartridge second housing seal arrangement form a radially directed seal with the axially extending main filter cartridge sealing flange. An air filter assembly according to claim 21 wherein:

(a) the main filter cartridge first housing seal arrangement forms an outwardly directed radial seal. An air filter assembly according to claim 22 wherein:

(a) the main filter cartridge first housing seal arrangement comprises a noncircular seal. An air filter assembly according to claim 23 wherein:

(a) the non-circular seal comprises alternating outwardly curved portions and inwardly directed portions. An air filter assembly according to claim 12 wherein:

(a) the access cover comprises a valve releasing water form inside the air filter assembly. An air filter assembly according to claim 12 wherein:

(a) the air filter assembly is constructed for vertical orientation when used on a vehicle so that the access cover is located on a bottom of the air filter assembly, and servicing of the air filter assembly is through a bottom opening when the access cover is removed. A vehicle comprising the filter assembly according to claim 12 provided in a vertical orientation so that the access cover is located on a bottom of the air filter assembly, and servicing of the air filter assembly is through a bottom opening when the access cover is removed.

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