WO2025240899A1 - Filter elements and assemblies - Google Patents

Abstract

An air filter cartridge for use within a housing assembly of an air cleaner can include a media pack including filter media extending from a first end to a second end; and a first end cap arranged at the first end of the media pack, the first end cap presenting an inner radial side defining a seal surface having a generally polygonal shape formed by a plurality of flat sides and adjoining corner portions, the first end cap having a first cross-sectional thickness extending through the flat sides that is greater than a second cross-sectional thickness extending through the corner portions.

Description

FILTER ELEMENTS AND ASSEMBLIES

RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 63/768.562, filed on March 7, 2025; U.S. Provisional Application Serial No. 63/715,456. filed on November 1. 2024; and U.S. Provisional Application Serial No. 63/649,173, filed on May 17, 2024, the disclosures of which are hereby incorporated by reference in their entireties.

FIELD OF THE DISCLOSURE

[0002] The present disclosure relates to the field of gas filtration, such as for instance air filtration. It relates to the field of filter assemblies comprising a filter element which is arranged in a filter housing in a sealing manner, such that air passing from an inlet of the housing to an outlet of the housing is filtered by the filter element. Preferably the assemblies are used for filtering air that is afterwards directed to an engine of for instance a vehicle.

BACKGROUND

[0003] Filter elements, also named filter cartridges, are used for a wide variety of filtering applications and the fluid to be filtered can be a liquid or a gas, e.g., air.

[0004] Indeed, in many instances, it is desired to filter contaminant material from a fluid stream. For example, airflow' streams to engines for motorized vehicles or for power generation equipment, construction equipment or other equipment, gas streams to gas turbine systems and air streams to various combustion furnaces, carry particulate contaminant therein. It is preferred for such systems that contaminant materials be removed from the fluid or at least be reduced.

[0005] Filter elements comprise filter media for removing contaminant materials when the fluid flows through the filter media. Commonly used and commercially available filter media are, for example, pleated media or fluted media. When the filter media is loaded with dust and/or particles above a certain threshold load, a filter element needs to be replaced. Filter elements are ty pically installed in the housing in a replaceable manner.

[0006] There is a need in industry' for new solutions which allow an easy installation of a correct filter element in a filter housing, especially complex filter housing designs, and which would not allow the installation of a wrong filter element. Complex filter housing designs can, for instance, be a result of boundary conditions imposed by the geometry^ and positioning of other vehicle/engine components. SUMMARY

[0007] An air filter cartridge for use within a housing assembly of an air cleaner can include a media pack including filter media extending from a first end to a second end; and a first end cap arranged at the first end of the media pack, the first end cap presenting an inner radial side defining a seal surface having a generally polygonal shape formed by a plurality’ of flat sides and adjoining comer portions, the first end cap having a first cross-sectional thickness extending through the flat sides that is greater than a second cross-sectional thickness extending through the comer portions.

[0008] In some examples, the first end cap is formed as a single, monolithic component.

[0009] In some examples, the first end cap includes a plurality of support members at least partially defining the first cross-sectional thickness.

[0010] In some examples, a distal axial end of the filter cartridge is defined by the end cap at a location that is radially aligned with the seal surface flat sides.

[0011] In some examples, the first end cap includes a seal member defining the inner radial side and defining an outer radial side, wherein the seal member is unsupported on the outer radial side at locations radially aligned with the seal surface comer portions.

[0012] In some examples, the first end cap includes a seal member defining the inner radial side and wherein the seal member has a constant cross-sectional thickness.

[0013] In some examples, the first end cap includes a seal member having a radial inner side defining the seal surface and a radial outer side defining a plurality of flat sides and adjoining inwardly extending comer portions.

[0014] In some examples, the first end cap includes a support band surrounding the radial outer side of the seal member.

[0015] In some examples, the seal surface is formed by a plurality of lip seals.

[0016] An air filter cartridge for use within a housing assembly of an air cleaner can include a media pack including filter media extending from a first end to a second end; a first end cap arranged at the first end of the media pack, the first end cap defining a first seal surface; and a second end cap removably sealed to the first end cap, the second end cap including an axial extension defining a second seal surface sealed against the first seal surface, the second end cap defining a third seal surface having a generally polygonal shape formed by a plurality of flat sides and adjoining comer portions.

[0017] In some examples, the second end cap includes a support member defining the second seal surface and a seal member defining the third seal surface. [0018] In some examples, the third seal surface is a radially inward facing seal surface.

[0019] In some examples, the third seal surface is a radially outward facing seal surface.

[0020] In some examples, the third seal surface is formed by a polyurethane seal member.

[0021] In some examples, the third seal surface is formed by a plurality of lip seals.

[0022] An air filter cartridge for use within a housing assembly of an air cleaner can include a media pack including filter media extending from a first end to a second end; and a first end cap arranged at the first end of the media pack, the first end cap presenting an outer radial side defining a seal surface having a generally polygonal shape formed by a plurality of flat sides and adjoining comer portions, the first end cap presenting an undercut surface located between the seal surface and the first end of the media pack.

[0023] In some examples, the first end cap includes a seal member having an outer radial side defining the seal surface and includes a plurality of support members radially supporting an inner radial side of the seal member.

[0024] In some examples, the media pack includes pleated media.

[0025] An air filter cartridge for use within a housing assembly of an air cleaner can include a media pack including filter media extending from a first end to a second end; and a first end cap arranged at the first end of the media pack, the first end cap presenting an outer radial side defining a seal surface having a generally polygonal shape formed by a plurality of flat sides and adjoining comer portions, wherein the seal surface is formed by a plurality of lip seals.

[0026] In some examples, the plurality of hp seals includes two to four lip seals.

[0027] In some examples, the end cap includes a support arrangement and wherein the plurality of hp seals are injection molded onto an outer radial surface of the support arrangement.

[0028] In some examples, the plurality of lip seals are formed from a thermoplastic elastomer material.

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] These and further aspects of the present disclosure will be explained in greater detail by way of example and with reference to the accompanying drawings in which:

[0030] Figure 1 is a schematic view of a first example of an air cleaner assembly having features in accordance with the present disclosure.

[0031] Figure 2 is a perspective exploded view of the air cleaner assembly shown in Figure 1.

[0032] Figure 3 is a cross-sectional side view of the air cleaner assembly shown in Figure 1.

[0033] Figure 4 is an enlarged portion of the cross-sectional side view presented in Figure 3. [0034] Figure 5 is a perspective view of a portion of an outlet assembly associated with the air cleaner assembly shown in Figure 1.

[0035] Figure 6 is a perspective view of a filter cartridge usable with the air cleaner shown in Figure 1.

[0036] Figure 7 is an exploded perspective view- of the filter cartridge show n in Figure 6.

[0037] Figure 8 is a perspective view of a filter cartridge usable with the air cleaner shown in Figure 1.

[0038] Figure 9 is an exploded perspective view' of the filter cartridge shown in Figure 8.

[0039] Figure 10 is a perspective view' of a filter cartridge usable with the air cleaner shown in Figure 1.

[0040] Figure 11 is an exploded perspective view of the filter cartridge shown in Figure 10. [0041] Figure 12 is a cross-sectional side view' of a filter cartridge usable with the air cleaner shown in Figure 1.

[0042] Figure 13 is an exploded perspective view of an end cap of the filter cartridge shown in Figure 12.

[0043] Figure 14 is a side view of an example air cleaner similar to that shown in Figure 1 but with a differently configured outlet tube assembly and filter cartridge end cap.

[0044] Figure 15 is a top view of the air cleaner assembly shown in Figure 14.

[0045] Figure 16 is a longitudinal cross-sectional side view of the air cleaner shown in Figure 14.

[0046] Figure 17 is an exploded side view of the air cleaner shown in Figure 14.

[0047] Figure 18 is a first exploded perspective view' of a seal ring of the air cleaner shown in Figure 14.

[0048] Figure 19 is a second exploded perspective view of the seal ring shown in Figure 18.

[0049] Figure 20 is a first end view of the seal ring shown in Figure 18.

[0050] Figure 21 is a second end view of the seal ring shown in Figure 18.

[0051] Figure 22 is a side view' of the seal ring shown in Figure 18.

[0052] Figure 23 is a side cross-sectional view of the seal ring shown in Figure 18.

[0053] Figure 24 is a perspective view of a filter cartridge usable with the air cleaners shown in Figures 1 and 14.

[0054] Figure 25 is an end view' of the filter cartridge shown in Figure 24.

[0055] Figure 26 is a longitudinal cross-sectional view of the filler cartridge shown in Figure 24.

[0056] Figure 27 is an enlarged portion of the cross-sectional view presented in Figure 26. [0057] Figure 28 is a perspective view of a filter cartridge usable with the air cleaners shown in Figures 1 and 14.

[0058] Figure 29 is an end view of the filter cartridge shown in Figure 28.

[0059] Figure 30 is a longitudinal cross-sectional view of the filter cartridge shown in Figure 28.

[0060] Figure 31 is an enlarged portion of the cross-sectional view presented in Figure 30.

[0061] Figure 32 is an exploded perspective view of an end cap usable with the filter cartridges shown in Figures 24 to 31.

[0062] Figure 32A is a side view' of the end cap shown in Figure 32.

[0063] Figure 33 is a schematic view of an example of an air cleaner assembly having features in accordance with the present disclosure.

[0064] Figure 33A is a side view of a filter cartridge associated with the air cleaner assembly shown in Figure 33.

[0065] Figure 33B is a cross-sectional view of the filter cartridge shown in Figure 33A.

[0066] Figure 33C is a top view of the filter cartridge shown in Figure 33A.

[0067] Figure 33D is a bottom view of the filter cartridge shown in Figure 33A.

[0068] Figure 33E is an exploded perspective view' of the filter cartridge shown in Figure 33A.

[0069] Figure 33F is a bottom perspective view of the filter cartridge shown in Figure 33A.

[0070] Figure 33G is an enlarged portion of the filter cartridge cross-sectional view of Figure 33B.

[0071] Figure 33H is a cross-sectional partial view of a seal member usable with any of the filter cartridges disclosed herein.

[0072] Figure 34 is a fragmentary, schematic, perspective view of a first example media type usable in arrangements according to the present disclosure.

[0073] Figure 35 is an enlarged, schematic, cross-sectional view' of a portion of the media ty pe depicted in Figure 34.

[0074] Figure 36 includes schematic views of examples of various fluted media definitions, for media of the type of Figures 34 and 35.

[0075] Figure 37 is a schematic view of an example process for manufacturing media of the ty pe of Figures 34-36.

[0076] Figure 38 is a schematic cross-sectional view of an optional end dart for media flutes of the type of Figures 34-37. [0077] Figure 39 is a schematic perspective view of a coiled filter arrangement usable in a filter cartridge having features in accord with the present disclosure, and made with a strip of media for example in accord with Figure 34.

[0078] Figure 40 is a schematic perspective view of a stacked media pack arrangement usable in a filter arrangement having selected features in accord with the present disclosure and made from a strip of media for example in accord with Figure 34.

[0079] Figure 41 is a schematic flow end view of a filter media pack using an alternate media to the media of Figure 34, and alternately usable in selected filter cartridges in accord with the present disclosure.

[0080] Figure 42 is a schematic opposite flow end view to the view of Figure 41.

[0081] Figure 43 is a schematic cross-sectional view of the media pack of Figures 41 and 42. [0082] Figure 44 is a schematic, fragmentary, cross-sectional view of a further alternate media type usable in a media pack of a filter cartridge having features in accord with the present disclosure.

[0083] Figure 45is a schematic, fragmentary cross-sectional view of a first variation of the media type of Figure 44.

[0084] Figure 46 is a schematic, fragmentary depiction of another usable fluted sheet/facing sheet combination in accord with the present disclosure.

[0085] Figure 47 is a fragmentary, second schematic view of the type of media in Figure 46 shown in a media pack.

[0086] Figure 48 is a schematic, fragmentary, plan view of still another media variation usable in arrangements according to the present disclosure.

[0087] Figure 49 is a schematic view of another variation of usable media in accord with the present disclosure.

[0088] Figure 50 is a schematic depiction of another usable fluted sheet/facing sheet combination in accord with the present disclosure.

[0089] Figure 51 is a perspective view of a portion of the usable fluted sheet/facing sheet combination depicted in Figure 50.

[0090] Figure 52 is a perspective view of another media variation usable in arrangements according to the present disclosure.

[0091] Figure 53 is a schematic, perspective view of a portion of a support section of the filter media of Figure 52, illustrated in a folded configuration but expanded or separated for illustrative purposes. [0092] Figure 54 is a schematic, cross-sectional view of a portion of the support section of the filter media of Figure 52. illustrated in a folded configuration but expanded or separated for illustrative purposes.

[0093] Figure 55 is a perspective view of another media variation useable in arrangements according to the present disclosure.

[0094] Figure 56 is a schematic depiction of an equipment assembly including an air cleaner assembly in accordance with any of the air cleaner assemblies disclosed herein.

[0095] The drawings of the figures are neither drawn to scale nor proportioned. Generally, identical components are denoted by the same reference numerals in the figures. Further, it is noted that many of the drawings presented herein are generated from computer-aided design (CAD) models that show parts in their nominal, undeformed states. In particular, for assembly views showing a filter cartridge installed within the housing, the seal member is depicted in its relaxed condition even though it would actually be compressed and/or stretched when installed against the outlet tube or other sealing surfaces associated with the air cleaner assembly. For example, in some views the seal member may appear to overlap with or intersect the outlet tube or seal plate geometry since the seal is shown in its pre-installation state rather than its deformed, installed state. A person having ordinary skill in the art would readily understand that such visual overlaps or intersections in the drawings represent the undeformed components and would interpret the drawings taking into account the compressible and/or stretchable nature of the seal member matenals during actual installation and use.

DETAILED DESCRIPTION

[0096] The present disclosure will be described in terms of specific embodiments, which are illustrative of the disclosure and not to be construed as limiting. It will be appreciated by persons skilled in the art that the present disclosure is not limited by what has been particularly shown and/or described and that alternatives or modified embodiments could be developed in the light of the overall teaching of this disclosure. The drawings described are only schematic and are non-limiting.

[0097] Use of the verb '‘to comprise’’, as well as the respective conjugations, does not exclude the presence of elements other than those stated. Use of the article “a”, ‘’an” or ‘'the” preceding an element does not exclude the presence of a plurality⁷ of such elements.

[0098] Furthermore, the terms first, second and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequence, either temporally, spatially, in ranking or in any other manner. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the disclosure described herein are capable of operation in other sequences than described or illustrated herein.

[0099] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiments is included in one or more embodiment of the present disclosure. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one ordinary skill in the art from this disclosure, in one or more embodiments.

[0100] As used herein, the term “axially” generally refers to a direction that is parallel to the longitudinal axis X while the term “radially” generally refers to a direction that is orthogonal to the longitudinal axis X. As also used herein, the term “radially inward” generally refers to a direction facing towards the longitudinal axis X while the term “radially outward” generally refers to a direction facing away from the longitudinal axis X.

[0101] Although a number of the drawings presented and discussed below are specifically addressing embodiments of a filter element for filtering air, the present disclosure is not limited thereto.

[0102] In Figure 56, a schematic depiction of an engine equipment arrangement 1360 is depicted. The equipment system 1360, in the example, comprises a vehicle or other equipment 361 having an internal combustion engine arrangement 1362 with a combustion air intake 1363. The equipment arrangement 1360 includes an air cleaner system 1365 having a filter arrangement 1366 therein, typically comprising a serviceable (i.e., removable and replaceable) filter cartridge. The air cleaner system 1365 and filter arrangement 1366 can include any of the below-described air cleaners and filter cartridges, and combinations thereof. Intake air to the system is shown at 1367 directed into the air cleaner assembly 1365 before filtering of unfiltered air through media of the filter cartridge arrangement 1366. At 1368, filtered air is shown being directed into the equipment air intake 1363. At 1370, optional equipment such as turbo system is shown. Of course, alternate equipment systems can be represented by arrangements analogous to those of Figure 56. The equipment system can be for example, an industrial air filter, an air cleaner arrangement used in association with a turbine, etc. The use in association with an internal combustion engine is typical, but not specifically required for many of the principles characterized herein. [0103] Referring to Figures 1 to 5, an air cleaner 10 is presented. In one aspect, the air cleaner assembly 10 includes an air cleaner housing 200 defining an interior volume within which a first filter cartridge 100 and a second filter cartridge 150 are disposed. It is noted that the air cleaner 10 can be configured such that only one of the first and second filter cartridges 100, 150 is provided. The air cleaner housing 200 is shown as being provided with a main housing body 202 and a cover 204. A mounting structure 201 for mounting the main housing body 202 to a structure is also shown. The air cleaner housing 200 also includes an outlet tube assembly 205 having joined together first and second parts 208, 210. In the example shown, the outlet tube assembly 205 is rotatable with respect to the main housing body 202. In one aspect, the first part 208 may be referred to as an inlet or outlet 208 while the second part 210 may be referred to as a receiver plate 210 or a sealing plate 210. wherein each defines a central opening for allowing air to pass therethrough. The air cleaner assembly 10 is also provided with an air inlet 202d. In some examples, assembly 205 can be configured as an air inlet while structure 202d can be configured as an air outlet. The air cleaner assembly 10 may also be provided with dust ejection port and valve assembly 202f.

[0104] In one aspect, the filter cartridge 100 includes filter media 102 extending between a first end cap 104 and a second end cap 106. In the particular example shown, the filter media 102 is pleated media arranged in a tubular manner to define a central opening 102c around an axis X. The filter cartridge 150 is similarly so constructed with filter media 152, a first end cap 153, and a second end cap 154, and is installed within the filter cartridge 100. As configured, each of the end caps 102, 153 forms a seal with the outlet tube assembly 205 such that air passing through the filter cartridge 100 must also pass through the filter cartridge 150 before exiting the housing assembly via outlet 202c. As detailed in a later section, many media types and configurations are possible for use with all of the disclosed example filter cartridges herein, for example, fluted media, z-media, depth media, non-pleated media, coiled media, and/or stacked media, etc.

[0105] In one aspect, the first end cap 104 is an open end cap and is connected to a first axial end 102a of the filter media 102 in a fluid tight manner. In one aspect, the second end cap 106 is a closed end cap and is connected to a second axial end 102b of the filter media 102 in a fluid tight manner. The first and second end caps 104, 106 can, for instance, be formed and attached to the filter cartridge 100 by a polyurethane potting process. In one aspect, the outermost portions of the end caps 104, 106. are generally annular or circular. The filter media 102 is also shown as being provided with an annular or circular shape with a hollow interior. Other shapes for the end caps 104, 106 and filter media 102 are possible, for example, elliptical shapes, obround, oval or race-track shapes, and/or conical shapes. The filter cartridge 150 is formed in a similar manner in which the end cap 154 is an open end cap and the end cap 153 is a closed end cap.

[0106] In one aspect, the end cap 104 includes a seal member 110 defining a radially inward facing surface 110a that has a generally polygonal cross-sectional shape in a relaxed state of the seal member 110. By use of the term ‘generally polygonal,’ it is meant to include true polygonal shapes that have flat sides with vertices and similar shapes with flat sides having rounded comers, and is meant to include shapes with flat sides having the same length and shapes with flat sides having different lengths. By use of the term ‘generally flat sides', it is meant to include surfaces that are entirely flat and surfaces which are generally flat with some degree of curvature, such as curvatures resulting from manufacturing processes. The term encompasses surfaces that maintain their generally flat characteristic while potentially having minor surface variations or features, provided such variations do not substantially alter the overall flat nature of the surface. Further, curved surfaces having a sagitta-to-chord ratio of an arc or curved surface of 10 percent of less would also be considered to be within the meaning of the term. Further, the term would also include bodies or members wherein a straight line can be drawn, within a thickness of the member, from one end of the member to the opposite end of the member. As is presented in examples herein, the filter cartridge sealing surface can also be a radially outward facing surface, as is shown for filter cartridge 150.

[0107] In the example presented, and with reference to the examples depicted at Figures 6 and 7, the seal surface 110a has a plurality of respective flat sides 110c joined together by radiused or curved comer portions 11 Od. The seal member 110 also defines a radially outward facing side I lOe having a plurality of flat sides 11 Of and inwardly extending corner portions 110g. Due to the presence of the inwardly extending comer portions 110g, the seal member 1 10 has a varying cross-sectional thickness in which a first thickness tl exists between the flat sides 110c, I lOf and in which a second thickness t2, less than the first thickness tl, exists between the comer portions 1 lOd, 110g. In one aspect, the reduction in material at the comer portions 110g may allow the seal member 110 to more readily expand at the comer portions 1 lOd when mounting the seal member 110 onto the outlet tube assembly 205. As shown, each of the surfaces 110a, 1 lOe has twelve flat sides and twelve comer portions. Other numbers of flat sides and comer portions are possible, such as three to eleven sides and comers or more than twelve sides and comers.

[0108] Figures 8 and 9 show a similar example to the filter cartridge 100, but wherein the end cap 104 is additionally provided with an outer support band 120 that follows the contours of the outer radial side 1 lOe and thus has flat sides and comer portions similar to flat sides 1 lOf and comer portions 110g. The support band 120 can be formed from a polymeric or metal material and can be either a separately formed and attached component, such as by an adhesive or other means, or overmolded onto the seal member 110. The support band 120 can function to radially support the seal member 110 such that the seal surface 110a is held in a greater compressive state against the outlet tube assembly 205. In some examples, the support band 120 is elastically deformable. In some examples, the support band 120 can be configured to have a thinner cross-section or less material at the location of the comer portions 110g such that the seal member 110 can elastically deform or stretch to a greater degree at the comer portions HOd in comparison to the flat sides 110c. In some examples, the support band 120 can be embedded within the material of the seal member 110 rather than being entirely external to the seal member 110, as is shown. Further, while the support band 120 is shown as having a solid surface, other configurations are possible. For example, the support band 120 could be provided with perforations or other types of openings, such as slots, or provided with axially extending fingers.

[0109] The outlet tube assembly 205 is further illustrated at Figures 3 to 5. In the example shown, the outlet tube assembly 205 includes a first part 208 and adjoining second part 210. In one aspect, the second part 210 may be referred to as a receiver plate 210 or a sealing plate 210. The second part 210 is shown as having a generally polygonal shaped sidewall 212 having a radially outward facing seal surface 212a with flat sides 212b and comer portions 212c that form a generally polygonal cross-sectional shape corresponding to the shape of the sealing surface 110a of the fdter cartridge 100. On the opposite side of the sidewall 212, a radially inward facing seal surface 212d is presented with flat sides 212e and comer portions 212f that form a generally polygonal cross-sectional shape corresponding to the shape of the sealing surface of the filter cartridge 150. With reference to Figure 5, the second part 210 is further provided with a sidewall 214 defining a radially inw ard facing radial surface having a plurality of spaced apart flat sections 214a interrupted by inwardly extending protrusions 214b having side edges 214c, 214d. Taken together, the surfaces 214a, 214c, and 214d form recessed areas 216 that can receive the outer portion of the seal member 110 such that the protrusions 214b are received within the inwardly extending comer portions 110g of the seal member 110. These features can also serve to rotationally align the fdter cartridge 100 into the proper orientation such that the flat sides 110c and comer portions 1 lOd are appropriately aligned with flat sides 212b and comer portions 212c. Once such alignment is achieved, the fdter cartridge can drop fully into place. [0110] Referring to Figures 10 to 13, an example is shown in which the end cap 104 is separable from the filter cartridge 100. As shown, the end cap 104 has the above-described features of a seal surface 1 10a have a generally polygonal shape. However, the end cap shown at Figures 10 to 13 includes a support structure 104a including an axial extension member 104b that forms a radially outward facing seal surface 104c. As most easily seen at Figure 11, the end cap 104 is provided with a radially inward facing seal surface 105a which is sized and configured to form a seal against the seal surface 104c of the extension member 104b. With such an arrangement, the end cap 104 can be inserted into an end cap 105 thereby enabling the filter cartridge 100 of Figures 10 to 13 to be installed onto a second part 210 configured for sealing with a polygonal shaped seal. In one aspect, the extension member 104b can include a distal radial protrusion 104d that, when the end caps 104, 105 are joined together, extends past the seal surface 105a and engages with a shelf or ledge 105b to aid in securing the end caps 104, 105 together. As most easily seen at Figures 12 and 13, the support structure 104a further includes a base portion 104e and a plurality of seal support members 104f that radially support the seal member 110 which is shown as having a generally polygonal shaped outer radial side. In such an arrangement, the seal member 110 has a constant cross-sectional thickness and the support members 104f have gaps 104g between them for accepting or receiving the inwardly extending protrusions 214 of the second part 210. In the example show n, the support members 104f extend slightly axially further than the seal member 110 to define an axial end of the filter cartridge 100, when installed. Such an arrangement can aid in guiding the filter cartridge 100 into the second part 210. In some examples, the seal member and support structure 104a depicted at Figures 10 to 13 are separately formed and attached together, such as by an adhesive. In some examples, the seal member 110 is formed first and the support structure 104a is overmolded onto the support structure 104a. In some examples, the support structure 104a is formed first and the seal member 110 is overmolded onto the support structure 104a. In some examples, the support structure 104a can be formed of a relatively rigid material, such as ABS plastic or polypropylene.

[OHl] As most easily viewed at Figures 2. the safety filter cartridge 150 is provided with filter media 152 extending between a first end cap 153 and a second end cap 154. In the particular example shown, the filter media 152 is non-pleated media arranged in a tubular manner to define a central opening. As detailed in a later section, many media types and configurations are possible for use with all of the disclosed example filter cartridges herein, for example, fluted media, z-media. depth media, non-pleated media, coiled media, and/or stacked media, etc. In one aspect, the second end cap 154 is an open end cap and has a seal member 156 presenting a radially outward facing sealing surface 156a defined by a plurality of flat sides 156b and adjoining rounded comer portions 156c. Accordingly, the sealing surface 156a of the second end cap 154 may be characterized as having a generally polygonal shape. In the example shown, eight flat sides 156b and eight comer portions 156c are provided that are aligned with the flat sides 212e and comer portions 212f of the seal surface 212d on the second part 210. More or fewer sides may be provided.

Examples of Figures 14 to 32A

[0112] Referring to Figures 14 to 32A another example of an air cleaner assembly 10 is presented. The air cleaner assembly 10 and related filter cartridge 100 are generally similar to the example shown at Figures 1 to 5. Accordingly, the above-provided description is generally applicable for this example where such similarities exist and not need be repeated here. This section will focus on the primary differences of the example shown at Figures 14 to 23 and the various compatible filter cartridges shown at Figures 24 to 32A. One primary difference with air cleaner assembly 10 is that a differently configured outlet tube assembly 205 is provided which presents a generally polygonal shaped seal surface that faces in a radially inward direction for sealing with a radially outward facing generally polygonal shaped seal of the filter cartridge 100. The outlet tube assembly 205 of this example also presents a generally polygonal shaped seal surface that faces in a radially inward direction for sealing with a radially outward facing generally polygonal shaped seal of the filter cartridge 150. The filter cartridge 150 is not shown in this example but can be generally similar in construction to that already shown and described in relation to Figures 1 to 5. Further, features of the filter cartridge 100 of this example could be used in a secondary filter cartridge 150. The outlet tube assembly 105 of this example is also different in that the second part 210 is provided as a two-part assembly with parts 211 and 213, as can be most easily seen at Figures 18 and 19. As also explained further herein, and in contrast to other depicted embodiments herein, the filter cartridges 1 0 show n in Figures 24 to 31 that can be used with the air cleaner assembly 10 have a plurality of lip seals

[0113] Referring to Figures 18 to 23, the outlet tube assembly second part 210 is shown as including a first part 211 and an interconnected second part 213. As shown, the first part 211 defines w all structure 212, located as an outer wall in this example, which presents a generally polygonal shaped seal surface 212a having flat sides 212b and comer portions 212c. As noted above, the seal surface 212a presents a radially inward directed seal surface against which the radially outward facing seal of the filter cartridge end cap 104 can form a seal. As shown, the second part 213 defines wall structure 214, located as an inner wall in this example, which presents a generally polygonal shaped seal surface 214e having flat sides 214f and comer portions 214g. As noted above, the seal surface 214e presents a radially inward directed seal surface against which the radially outward facing seal of the filter cartridge end cap 154 can form a seal. The wall structure 214 is additionally provided with radially outwardly extending protrusions 214b that extend towards the wall structure 212. As most easily seen at Figure 20, the protrusions 214b are radially aligned with the comer portions of the wall structures and extend into a polygonal shaped annulus or recess 216 defined between the wall structures 212, 214. In one aspect, the parts 211, 213 can be provided with snap-fit type and/or interlocking type connection features 212h. 214h to enable the parts 211, 213 to be connected to each other to form an assembled second part 210. Further, as most easily viewed at Figures 18, 19, and 23, the wall structure 212 can be provided with spaced apart radially inward protrusions 212g radially aligned with the comer portions 212b to form an undercut feature in which the seal surface 212a is recessed from the innermost portion of the protrusions 212g. With such a feature, the seal member 110 of the filter cartridge end cap 104 deforms inwardly as the seal member 110 moves past the protrusions 212g and then, in an installed state as shown at Figure 16, moves towards the seal surface 212a to form the seal while accommodating the presence of the protrusions at a location between the seal surface 212a and the end of the media pack 102. The disclosed protrusion arrangement 212g can be characterized as forming part of a local or localized undercut arrangement. Other configurations are possible. For example, the protrusions 212g can be additionally or alternatively aligned along the flat sides 212b. In another example, a single protrusion 212g extends continuously around the entire perimeter boundary of the wall 212. As the second part 210 is formed from two separate pieces 211, 213, moldability is improved, particularly with respect to providing features like protmsions 212g. [0114] Referring to Figures 24 to 27, aspects of the filter cartridge 100 suitable for use with the housing assembly 200 are further illustrated. As show n, the filter cartridge is provided with a media pack 102 extending betw een end caps 104, 106 with the end cap 104 defining a central opening for allowing air to flow therethrough and the end cap 106 being a closed end cap. In one aspect, the media pack 102 is supported by an inner and outer apertured liner 103a, 103b. In the example shown, the filter cartridge end cap 104 has a support arrangementl08 molded or otherwise secured to the media pack that has a generally polygonal shaped axial extension 108a that supports a seal member 110. In one aspect, an axial extension 108a is provided with axially extending slots 108b located at the comer portions and configured to receive the protrusions 214b of the second part 210. Such an arrangement can help to rotationally guide the cartridge 100 into the proper rotational orientation before further inserting the cartridge 100 into the housing. This arrangement can also ensure that a proper fdter cartridge 100 designed for the air cleaner 10 is utilized. It is noted that, when the filter cartridge 100 is installed, the protrusions 214b can also function to provide radial support to the exposed portion of the seal member 110 such that an effective seal is better ensured at the comer portions.

[0115] In one aspect, the seal member 110 is formed with a lip seal configuration rather than being solid as is shown in other examples. In one aspect, the seal member 110 is made of a relatively flexible material and may be referred to herein as a “flexible sealing member,” and forms a radial (i. e. , facing in a direction or plane(s) parallel to the longitudinal axis of the filter cartridge) sealing member. In the example shown, the flexible material is an injection-molded thermoplastic elastomer (TPE) and/or thermoplastic polyester elastomers (TPEE) and the material for the support arrangement 108 is a polypropylene material. In one example, the sealing member 110 is provided as an injection-molded gasket that is molded directly onto the support arrangement 108.

[0116] As most easily seen at Figure 27, the support arrangement 108 can be provided with overhanging portions 108c, 108d that aid in retaining the seal member 110 onto the support arrangement 108. As illustrated at Figures 32 and 32A, the axial extension 108a of the support arrangement 108 can also be provided with a plurality⁷ of radially extending posts 108f along the flat sides and/or comer portions that are received by similarly shaped openings 11 Oh in the seal member 110 to further enhance retainment of the seal member 1 10 onto the axial extension 108a. In addition to or as an alternative, and as also shown at Figures 32 and 32A, the seal member 110 may be provided with a circumferential protrusion HOi that is received by a circumferential groove 108g of the support arrangement 108, for example at the location of the axial extension 108a. The opposite arrangement is also possible with a protrusion provided on the support arrangement 108 and a groove provided on the seal member 1 10. Multiple grooves and protrusions, and combinations thereof, may be provided on each of the seal member 110 and support arrangement. Figures 32 and 32A also illustrate that the axial extension 108a may be provided as a uniform or continuous sidewall without slots. The seal member 110 may also be formed from other materials, such as polyurethane.

[0117] In the embodiment shown, the sealing member 110 is provided as an injection-molded gasket with a pair of radially acting, parallel lip seals 117 (117a, 117b). In one aspect, the lip seals 117 can be characterized as outwardly directed radial seals that seal against the sealing surface 212a of the second part 210. Although two lip seals are shown, more or fewer may be provided, such as three or four lip seals. In some examples, the filter cartridge 100 can be configured with lips seals 117 that face in a radially inward direction to seal against a housing surface that faces in a radially outward direction.

[0118] Figures 24 to 31 also illustrated that the seal member 110 can have an undercut or recessed portion 118 below the lip seals 117 for receiving a correspondingly shaped radial protrusion formed by the second part 210. With such a construction, seal member 110 must initially compress to accommodate the radial protrusion of the second part 210. After sufficient axial displacement of the filter cartridge 100, the lip seals 1 17 move past the radial protrusion and come into sealing contact with seal surface 212d. To accommodate this compression, reinforcement members 109 provided on the support arrangement 108 can optionally be configured to deflect radially inward during the insertion process. In the example shown at Figures 24 and 25. the undercut portion 118 extends continuously around the perimeter of the seal member 110. It is noted that the reinforcement members 109 can also function to radially support the seal member 108 after installation to aid in maintaining a seal against the second part 210.

[0119] Referring to Figures 28 to 31, a variation of the filter cartridge 100 shown in Figures 24 to 27 is presented. In this example, the support arrangement 108 is formed as a separate component that is secured to the media pack 102 by an anchoring arrangement 111 formed from a seal material that bonds the support arrangement 108 to the media pack 102. As shown, the support arrangement 108 includes a plurality of apertures 108e through which material of the anchoring arrangement 111 can flow to form rivet type features I l la with heads for further securing the support arrangement 108 to the media pack 102.

[0120] Referring to Figures 32 and 32A, a further variation of the filter cartridge 100 shown in Figures 24 to 27 is presented.

[0121] Although the above-described filter cartridges 100, 150 are shown as having seal members 1 10 with seal surfaces defining a polygonal shape with eight sides, more or fewer sides may be provided. Further, the seal surfaces may be provided in other shapes besides polygon shapes such as circular, oval, or elliptical shapes.

Examples of Figures 33 to 33F

[0122] Referring to Figures 33 to 33F another example of an air cleaner assembly 10 and filter cartridge 100 is presented. As shown at Figure 33, the air cleaner assembly 10 includes a housing 200 having a housing body 202 and a cover 204 that cooperatively house a filter cartridge 100 and that define an inlet 202d and an outlet 202c. In one aspect, the housing body 202 presents an inwardly facing generally polygonal shaped radial seal surface, similar to those described above, for sealing against a seal member 110 of the fdter cartridge. As most easily seen at Figures 33A and 33B, the filter cartridge 100 is shown as having a media pack formed from fluted media. Other media types are possible. The filter cartridge 100 is also shown as having a relatively rigid seal carrier or support structure 108 that supports a relatively soft seal member 110. As can be seen at Figures 33A and 33B. the seal member 110 is located between the axial ends or flow faces of the media pack 102. Accordingly, the seal member 110 can be characterized as circumscribing the media pack 102. The support structure 108 is shown as being bonded directly to the exterior of the media pack 102. Other configurations are possible. For example, the support structure 108 can be configured to completely surround the media pack 102. As most easily seen at Figures 33C and 33D, the seal member 110 presents a radially outward facing surface that is generally polygonal in shape. As can be seen at Figure 33B. the support structure 108, at the location where the seal member 110 is supported, extends axially and is spaced radially from the media pack 102 such that a gap 113 exists between the media pack outer perimeter 102 and the support structure 108 at the location of the seal. Other configurations are possible. As most easily seen at Figure 33E, the support structure 108 is provided with a plurality of spaced apart reinforcement members 109 that support the inner radial side of the seal member 110. In one aspect, the reinforcement members 109 extend along the flat sides of the seal member 110 such that gaps between the reinforcement members 109 are radially aligned with the comer portions of the seal member 110, as is most easily viewed at Figure 33D. The reinforcement members 109 are generally flat and arranged to form a generally polygonal shape matching that of the seal member 110.

[0123]

[0124] In the embodiment shown, and as most easily seen at Figure 33G, the sealing member 110 is provided as an injection-molded gasket with a pair of radially acting, parallel lip seals 1 17 (1 17a, 1 17b). In one aspect, the lip seals 1 17 can be characterized as outwardly directed radial seals that seal against the sealing surface 212a of the second part 210. Although two lip seals are shown, more or fewer may be provided, such as three or four lip seals. In some examples, the filter cartridge 100 can be configured with lips seals 117 that face in a radially inward direction to seal against a housing surface that faces in a radially outward direction. In contrast to the earlier-shown lip seal embodiments, which have lip seals that extend at an oblique angle to the longitudinal axis of the filter cartridge in a direction away from the end of the media pack to which the seal member 110 is most proximate, the lip seals 117 of this example extend upwardly at an oblique angle to the longitudinal axis towards the end of the media pack closest to the seal member 110. Seal member 110 can also include a bumper portion 117c for helping to maintain the central location of the cartridge 100 within the housing. Figure 33H shows an example of a single lip seal 117 which may be used for any of the examples having such seals herein.lt is noted that the above-described concepts, features, and alternatives for filter cartridges 100 and 150 are interchangeable such that features shown and described for filter cartridge 100 are applicable to filter cartridge 150, and vice versa. Further, each of the above-described examples having generally polygonal shapes may be provided with any suitable number of sides and comer portions and are not constrained to any particular number of sides.

Example Media Configurations. Generally

[0125] Any type of filter media can be used as the media pack 102, 152 for the abovedisclosed filter cartridges 100. 150 as further described herein with relation to Figures 34-55. Further, the media type for filter cartridge 100 may be the same type or a different type of media than that for an associated filter cartridge 150 that may also be present in the air cleaner housing. For example, the filter cartridge 100 may have pleated or fluted type media while another filter cartridge 150 may be provided with fluted or pleated type media, respectively.

[0126] The media can be of a variety’ of types and configurations, and can be made from using a variety of materials. For example, pleated media arrangements can be used in cartridges according to the principles of the present disclosure, as discussed below-.

[0127] The principles are particularly well adapted for use in situations in which the media is quite deep in extension between the inlet and outlet ends of the cartridge, but alternatives are possible. Also, the principles are often used in cartridges having relatively large crossdimension sizes. With such arrangements, alternate media types to pleated media w ill often be desired.

[0128] In this section, examples of some media arrangements that are usable with the techniques described herein are provided. It will be understood, however, that a variety of alternate media types can be used. The choice of media type is generally one of preference for: availability, function in a given situation of application, ease of manufacturability, etc., and the choice is not necessarily specifically related to the overall function of selected ones of various filter cartridge/air cleaner interaction features characterized herein.

A, Media Pack Arrangements Using Filter Media Having Media Ridges (flutes)

Secured to Facing Media [0129] Fluted filter media (media having media ridges) can be used to provide fluid filter constructions in a variety of manners. One well known manner is characterized herein as a z- filter construction. The term "z-filter construction" as used herein, is meant to include (but not be limited) a type of filter construction in which individual ones of corrugated, folded or otherwise formed filter flutes are used to define (typically in combination with facing media) sets of longitudinal, typically parallel, inlet and outlet filter flutes for fluid flow through 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; 6,350,291; 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 cited references being incorporated herein by reference.

[0130] 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 or sheet section, and (2) a facing media sheet or sheet section. The facing media sheet is typically non-corrugated, however it can be corrugated, for example perpendicularly to the flute direction as described in PCT Publication WO 2005/077487. incorporated herein by reference.

[0131] The fluted media section and facing media section can comprise separate materials between one another. How ever, they can also be sections of the single media sheet folded to bring the facing media material into appropriate juxtaposition with the fluted media portion of the media. For example, a single continuous sheet of media formed with alternating fluted and flat sections along the length of the media can be folded upon itself in zig-zag fashion to form a fluted media configuration.

[0132] The fluted (typically corrugated) media sheet and the facing media sheet or sheet section together, are typically used to define media having parallel flutes. In some instances, the fluted sheet and facing sheet are separate and then secured together and are then coiled, as a media strip, to form a z-filter media construction. Such arrangements are described, for example, in U.S. 6,235.195 and U.S. 6,179.890, each of which is incorporated herein by reference. In certain other arrangements, some non-coiled sections or strips of fluted (typically corrugated) media secured to facing media, are stacked with one another, to create a filter construction. An example of this is described in Figure 11 of U.S. 5,820,646, incorporated herein by reference.

[0133] Herein, strips of material comprising fluted sheet (sheet of media with ridges) secured to corrugated sheet, which are then assembled into stacks to form media packs, are sometimes referred to as "single facer strips,” “single faced strips,” or as “single facer" or “single faced” media. The terms and variants thereof, are meant to refer to a fact that one face, i.e., a single face, of the fluted (typically corrugated) sheet is faced by the facing sheet, in each strip.

[0134] Typically, coiling of a strip of the fluted sheet/facing sheet (i.e., single facer) combination around itself, to create a coiled media pack, is conducted with the facing sheet directed outwardly. Some techniques for coiling are described in PCT Publication WO 2004/082795, 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. [0135] The term "corrugated" used herein to refer to structure in media, is often used 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 corrugations in the resulting media, he term "corrugation" is however, not meant to be limited to such flutes, unless it is stated that they result from flutes that are by techniques involving passage of media into a bite between corrugation rollers. 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 Publication WO 2004/007054 incorporated herein by reference.

[0136] Corrugated media is a specific form of fluted media. Fluted media is media which has individual flutes or ridges (for example formed by corrugating or folding) extending thereacross.

[0137] 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 or cartridges 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 "serviceable" in this context is meant to refer to a media containing filter cartridge that is periodically removed and replaced from a corresponding fluid (e.g. air) cleaner. In some instances, each of the inlet flow end (or face) and outlet flow end (or face) will be generally flat or planar, with the two parallel to one another. However, variations from this, for example non-planar faces, are possible.

[0138] A straight through flow configuration (especially for a coiled or stacked media pack) is, for example, in contrast to serviceable filter cartridges such as cylindrical pleated filter cartridges of the type shown in U.S. 6.039,778, incorporated herein by reference, in which the flow generally makes a substantial turn as its passes into and out of the media. That is, in a U.S. 6,039,778 filter, the flow enters the cylindrical filter cartridge through a cylindrical side, and then turns to exit through an open end of the media (in forward-flow systems). In a typical reverse-flow system, the flow enters the serviceable cylindrical cartridge through an open end of the media and then turns to exit through a side of the cylindrical fdter media. An example of such a reverse-flow system is show n in U.S. 5,613,992, incorporated by reference herein.

[0139] The term "z-filter media construction" and variants thereof as used herein, without more, is meant to include, but not necessarily be limited to. any or all of: a web of corrugated or otherwise fluted media (media having media ridges) secured adjacent to (facing) media, whether the sheets are separate or part of a single web, with appropriate sealing (closure) to allow for definition of inlet and outlet flutes; and/or a media pack constructed or formed from such media into a three dimensional network of inlet and outlet flutes; and/or, a filter cartridge or construction including such a media pack.

[0140] In Figure 34, an example of media 1001 usable in z-filter media construction is shown. The media 1001 is formed from a fluted, in this instance corrugated, sheet 1003 and a facing sheet 1004. A construction such as media 1001 is referred to herein as a single facer or single faced strip.

[0141] Sometimes, the corrugated fluted or ridged sheet 1003, shown in Figure 34, is of a ty pe generally characterized herein as having a regular, curved, wave pattern of flutes, ridges, or corrugations 1007. The term "wave pattern" in this context, is meant to refer to a flute, ridge or corrugated pattern of alternating troughs 1007b and ridges 1007a. The term "regular" in this context is meant to refer to the fact that the pairs of troughs and ridges (1007b, 1007a) alternate with generally the same repeating corrugation (flute or ridge) shape and size. (Also, typically in a regular configuration each trough 1007b is substantially an inverse ridge for each ridge 1007a.) The term "regular" is thus meant to indicate that the corrugation (or flute) pattern comprises troughs (inverted ridges) 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 1003 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 1001 could be terminated, for example, betw een a pair comprising a ridge and a trough, or partially along a pair comprising a ridge and a trough. (For example, in Figure 34. the media 1001 depicted in fragmentary has eight complete ridges 1007a and seven complete troughs 1007b.) 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.

[0142] In the context of the characterization of a "curved" wave pattern of corrugations, in certain instances the corrugation pattern is not the result of a folded or creased shape provided to the media, but rather the apex of each ridge 1007a and the bottom of each trough 1007b is formed along a radiused curve. A typical radius for such z-filter media would be at least 0.25 mm and typically would be not more than 3 mm.

[0143] An additional characteristic of the particular regular, curved, wave pattern depicted in Figure 34, for the corrugated sheet 1003, is that at approximately a midpoint region 1030 between each trough and each adjacent ridge, along most of the length of the flutes 1007, is located a transition region where the curvature inverts. For example, viewing a back side or face 1003a, in Figure 34, trough 1007b is a concave region, and ridge 1007a is a convex region. Of course, when viewed toward front side or face 1003b, trough 1007b of side 1003a forms a ridge; and ridge 1007a of face 1003a, forms a trough. (In some instances, region 1030 can be a straight segment, instead of a point, with curvature inverting at ends of the region 1030.) [0144] A characteristic of the particular regular, wave pattern fluted (in this instance corrugated) sheet 1003 shown in Figure 34, is that the individual corrugations, ridges or flutes are generally straight, although alternatives are possible. By "straight" in this context, it is meant that through at least 70%, typically at least 80% of the length, the ridges 1007a and troughs (or inverted ridges) 1007b do not change substantially in cross-section. The term "straight" in reference to corrugation pattern shown in Figure 34, in part distinguishes the pattern from the tapered flutes of corrugated media described in Figure 1 of PCT Publication WO 97/40918 and PCT Publication 2003/47722, each of which is incorporated herein by reference. The tapered flutes of Figure 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.

[0145] Referring to Figure 34 and as referenced above, the media 1001 has first and second opposite edges 1008 and 1009. When the media 1001 is formed into a media pack, in general edge 1009 will form an inlet end or face for the media pack and edge 1008 will form an outlet end or face, although an opposite orientation is possible.

[0146] In the example depicted, the various flutes 1007 extend completely between the opposite edges 1008, 1009, but alternatives are possible. For example, they can extend to a location adjacent or near the edges, but not completely therethrough. Also, they can be stopped and started partway through the media, as for example in the media of U.S. Publication 2014/0208705, incorporated herein by reference.

[0147] When the media is as depicted in Figure 34, adjacent edge 1008 can provided a sealant bead 1010, sealing the corrugated sheet 3 and the facing sheet 1004 together. Bead 1010 will sometimes be referred to as a "single facer" or “single face” bead, or by variants, since it is a bead between the corrugated sheet 1003 and facing sheet 1004, which forms the single facer (single faced) media strip 1001. Sealant bead 1010 seals closed individual flutes 1011 adjacent edge 1008, to passage of air therefrom (or thereto in an opposite flow).

[0148] In the media depicted in Figure 34, adjacent edge 1009 is provided seal bead 1014. Seal bead 1014 generally closes flutes 1015 to passage of unfiltered fluid therefrom (or flow therein in an opposite flow), adjacent edge 1009. Bead 1014 would typically be applied as media 1001 is configured into a media pack. If the media pack is made from a stack of strips 1001, bead 1014 will form a seal betw een a backside 1017 of facing sheet 1004, and side 1018 of the next adjacent corrugated sheet 1003. When the media 1001 is cut in strips and stacked, instead of coiled, bead 1014 is referenced as a "stacking bead." (When bead 1014 is used in a coiled arrangement formed from a long strip of media 1001, it may be referenced as a "winding bead.").

[0149] In alternate types of through-flow' media, seal material can be located differently, and added sealant or adhesive can even be avoided. For example, in some instances, the media can be folded to form an end or edge seam, or the media can be sealed closed by alternate techniques such as ultrasound application, etc. Further, even when sealant material is used, it need not be adjacent opposite ends.

[0150] Referring to Figure 34, once the filter media 1001 is incorporated into a media pack, for example by stacking or coiling, it can be operated as follows. First, air in the direction of arrows 1012, would enter open flutes 101 1 adj acent end 1009. Due to the closure at end 1008, by bead 1010, the air w ould pass through the filter media 1001, for example as show n by arrow's 1013. It could then exit the media or media pack, by passage through open ends 1015a of the flutes 1015, adjacent end 1008 of the media pack. Of course, operation could be conducted with air flow in the opposite direction.

[0151] For the particular arrangement shown herein in Figure 34, the parallel corrugations 1007a, 1007b are generally straight completely across the media, from edge 1008 to edge 1009. Straight flutes, ridges 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." [0152] Z-filter constructions which do not utilize straight, regular curved wave pattern corrugation 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 Figures 1 and 3, of Yamada ’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 Figure 2 of Matsumoto '326. In Ishii, et al. U.S., 4,925,561, (Figure 1) flutes folded to have a rectangular cross section are shown, in which the flutes taper along their lengths. In WO 97/40918 (Figure 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. Yamada '825, Matsumoto '326, Ishii '561, and WO 97/40918 are incorporated herein by reference. Also, flutes, which are modified in shape to include various ridges, are known.

[0153] 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 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 corrugated configuration, during use. [0154] Typically, in the corrugation 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 flute or corrugations will tend to spring back, recovering only a portion of the stretch and bending that has occurred. The facing media sheet is sometimes tacked to the fluted media sheet, to inhibit this spring back in the corrugated sheet. Such tacking is show n at 1020. [0155] 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.

[0156] The media of the corrugated (fluted) sheet 1003, facing sheet 1004, or both, can be provided with a fine fiber material on one or both sides thereof, for example in accordance with U.S. 6,673,136, incorporated herein by reference. In some instances, when such fine fiber material is used, it may be desirable to provide the fine fiber on the upstream side of the material and inside the flutes. When this occurs, air flow, during filtering, will typically be into the edge comprising the stacking bead.

[0157] An issue with respect to z-filter constructions relates to closing of the individual flute ends. Although alternatives are possible, 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 and sealant for flute seals, large sealant surface areas (and volume) at both the upstream end and the downstream end are needed. High quality' seals at these locations are important to proper operation of the media structure that results. The high sealant volume and area, creates issues with respect to this.

[0158] Attention is now directed to Figure 35, in which z-filter media; i.e., a z-filter media construction 1040. utilizing a regular, curved, wave pattern corrugated sheet 1043. and a noncorrugated flat sheet 1044, i.e., a single facer strip is schematically depicted. A distance DI, between points 1050 and 1051, defines the extension of flat sheet 1044 in region 1052 underneath a given corrugated flute 1053. A length or distance D2 of the arcuate media for the corrugated flute 1053, over the same distance DI is of course larger than DI. due to the shape of the corrugated flute 1053. For a typical regular-shaped media used in fluted filter applications, the linear length D2 of the media 1053 between points 1050 and 1051 will often be at least 1.2 times DI. Typically, D2 would be within a range of 1.2 to 2.0 times DI, inclusive. One particularly convenient arrangement for air filters has a configuration in which D2 is about 1.25 to 1.35 times DI. Such media has, for example, been used commercially in Donaldson Powercore™ Z-filter arrangements. Another potentially convenient size would be one in which D2 is about 1.4 to 1.6 times DI. Herein the ratio D2/D1 will sometimes be characterized as the flute/flat ratio or media draw for the corrugated media.

[0159] 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 136 in combination with Table A below provides definitions of these flutes.

[0160] Donaldson Company , Inc., (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.

TABLE A

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

[0161] In 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.

[0162] It is noted that alternative flute definitions such as those characterized in U.S. Publication 2009/0127211; U.S. Publication 2008/0282890; and/or U.S. Publication 2010/0032365 can be used, with air cleaner features as characterized herein below. The complete disclosures of each of U.S. 2009/0127211, U.S. 2008/0282890, and U.S. 2010/0032365 are incorporated herein by reference.

[0163] Another media variation comprising fluted media with facing media secured thereto, can be used in arrangements according to the present disclosure, in either a stacked or coiled form, is described in U.S. Publication 2014/0208705, owned by Baldwin Filters, Inc. and incorporated herein by reference.

B, Manufacture of Media Pack Configurations Including the Media of Figures 34-36, see Figures 37-38 [0164] In Figure 37, one example of a manufacturing process for making a media strip (single facer) corresponding to strip 1001 of Figure 34 is shown. In general, a facing sheet 1064 and a fluted (corrugated) sheet 1066 having flutes 1068 are brought together to form a media web 1069, with an adhesive bead located therebetween at 1070. The adhesive bead 1070 will form a single facer bead 1010, see Figure 34. An optional darting process occurs at station 1071 to form center darted section 1072 located mid-web. The z-filter media or Z-media strip 1074 can be cut or slit at 1075 along the bead 1070 to create two pieces or strips 1076, 1077 of z-filter media 1074, 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.

[0165] Techniques for conducting a process as characterized with respect to Figure 37 are described in PCT Publication WO 2004/007054, incorporated herein by reference.

[0166] Still in reference to Figure 37, before the z-filter media 1074 is put through the darting station 1071 and eventually slit at 1075, it must be formed. In the schematic shown in Figure 37, this is done by passing a sheet of filter media 1092 through a pair of corrugation rollers 1094, 1095. In the schematic shown in Figure 37, the sheet of filter media 1092 is unrolled from a roll 1096, wound around tension rollers 1098, and then passed through a nip or bite 1102 between the corrugation rollers 1094, 1095. The corrugation rollers 1094, 1095 have teeth 1104 that will give the general desired shape of the corrugations after the flat sheet 1092 passes through the nip 1102. After passing through the nip 1 102, the sheet 1092 becomes corrugated across the machine direction and is referenced at 1066 as the corrugated sheet. The corrugated sheet 1066 is then secured to facing sheet 1064. (The corrugation process may involve heating the media, in some instances.)

[0167] Still in reference to Figure 37, the process also shows the facing sheet 1064 being routed to the darting process station 1071. The facing sheet 1064 is depicted as being stored on a roll 1106 and then directed to the corrugated sheet 1066 to form the Z-media 1074. The corrugated sheet 1066 and the facing sheet 1064 would typically be secured together by adhesive or by other means (for example, by sonic welding).

[0168] Referring to Figure 37, an adhesive line 1070 is shown used to secure corrugated sheet 1066 and facing sheet 1064 together, as the sealant bead. Alternatively, the sealant bead for forming the facing bead could be applied as shown as 1070a. If the sealant is applied at 1070a, it may be desirable to put a gap in the corrugation roller 1095, and possibly in both corrugation rollers 1094, 1095, to accommodate the bead 1070a. [0169] Of course, the equipment of Figure 37 can be modified to provide for the tack beads 1020 of Figure 34. if desired.

[0170] 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 1094, 1095. One useful corrugation pattern will be a regular curved wave pattern corrugation, of straight flutes or ridges, as defined herein above. A typical regular curved wave patern used, would be one in which the distance D2, as defined above, in a corrugated patern is at least 1.2 times the distance DI as defined above. In example applications, typically D2 = 1.25 to 1.35 times DI, although alternatives are possible. In some instances, the techniques may be applied with curved wave paterns that are not "regular," including, for example, ones that do not use straight flutes. Also, variations from the curved wave paterns shown, are possible.

[0171] As described, the process shown in Figure 37 can be used to create the center darted section 1072. Figure 38 show's, in cross-section, one of the flutes 1068 after darting and sliting. [0172] A fold arrangement 1118 can be seen to form a darted flute 1120 with four creases 1121a, 1121b, 1121c, 1121d. The fold arrangement 1118 includes a flat first layer or portion 1122 that is secured to the facing sheet 1064. A second layer or portion 1124 is shown pressed against the first layer or portion 1122. The second layer or portion 1124 is preferably formed from folding opposite outer ends 1126, 1127 of the first layer or portion 1122.

[0173] Still referring to Figure 38, two of the folds or creases 1121a, 1121b 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 1120, when the fold 1120 is view ed in the orientation of Figure 38. The term "inwardly directed" is meant to refer to the fact that the fold line or crease line of each crease 1121a, 1121b, is directed tow ard the other.

[0174] In Figure 38, creases 1 121c, 1121 d, will generally be referred to herein as "lower, outw ardly directed" creases. The term "lower" in this context refers to the fact that the creases 1121c, 1121 d are not located on the top as are creases 1121a, 1121b, in the orientation of Figure 38. The term "outwardly directed" is meant to indicate that the fold lines of the creases 1121c, 112 Id are directed away from one another.

[0175] The terms "upper" and "lower" as used in this context are meant specifically to refer to the fold 1120, when viewed from the orientation of Figure 38. That is, they are not meant to be other ise indicative of direction when the fold 1120 is oriented in an actual product for use. [0176] Based upon these characterizations and review of Figure 38, it can be seen that a regular fold arrangement 1118 according to Figure 38 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.

[0177] A third layer or portion 1128 can also be seen pressed against the second layer or portion 1124. The third layer or portion 1128 is formed by folding from opposite inner ends 1134, 1135 of the third layer 1128.

[0178] Another way of viewing the fold arrangement 1118 is in reference to the geometry of alternating ridges and troughs of the corrugated sheet 1066. The first layer or portion 1122 is formed from an inverted ridge. The second layer or portion 1124 corresponds to a double peak (after inverting the ridge) that is folded toward, and in preferred arrangements, folded against the inverted ridge.

[0179] Techniques for providing the optional dart described in connection with Figure 38, in a preferred manner, are described in PCT Publication WO 2004/007054, incorporated herein by reference. Techniques for coiling the media, with application of the winding bead, are described in PCT Publication WO 2004/082795, and incorporated herein by reference.

[0180] Alternate approaches to darting the fluted ends closed are possible. Such approaches can involve, for example: darting which is not centered in each flute; and rolling, pressing or folding over the various flutes. In general, darting involves folding or otherwise manipulating media adjacent to fluted end, to accomplish a compressed, closed, state.

[0181] Techniques described herein are particularly well adapted for use in media packs that result from a step of coiling a single sheet comprising a corrugated sheet/facing sheet combination, i.e., a "single facer" strip. However, they can also be made into stacked arrangements.

[0182] Coiled media or 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 or media pack. Typical shapes are circular as described in PCT Publication WO 2004/007054. Other usable shapes are obround, some examples of obround being oval shape. In general, oval shapes have opposite curved ends attached by a pair of opposite sides. In 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 Publications WO 2004/007054 and WO 2004/082795, each of which is incorporated herein by reference. [0183] 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.

[0184] Opposite flow ends or flow faces of the media or media pack can be provided with a variety of different definitions. In many arrangements, the ends or end faces are generally flat (planer) and perpendicular to one another. In other arrangements, one or both of the end faces include tapered, for example, 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.

[0185] The flute seals (for example from the single facer bead, winding bead or stacking bead) can be formed from a variety of materials. In various ones of the cited and incorporated references, hot melt or polyurethane seals are described as possible for various applications.

[0186] In Figure 39, a coiled media pack (or coiled media) 1130 constructed by coiling a single strip of single faced media is depicted, generally. The particular coiled media pack depicted is an oval media pack 1130a, specifically a racetrack shaped media pack 1131. The tail end of the media, at the outside of the media pack 1130 is shown at 1 13 lx. It will be typical to terminate that tail end along straight section of the media pack 1130 for convenience and sealing. Typically, a hot melt seal bead or seal bead is positioned along that tail end to ensure sealing. In the media pack 130. the opposite flow (end) faces are designated at 1132, 1133. One would be an inlet flow end or face, the other an outlet flow end or face.

[0187] In Figure 40, there is (schematically) shown a step of forming stacked z-filter media (or media pack) from strips of z-fdter media, each strip being a fluted sheet secured to a facing sheet. Referring to Figure 40, single facer strip 1200 is being shown added to a stack 1201 of strips 1202 analogous to strip 1200. Strip 1200 can be cut from either of strips 1076, 1077, Figure 37. At 1205 in Figure 40, application of a stacking bead 1206 is shown, between each layer corresponding to a strip 1200, 1202 at an opposite edge from the single facer bead or seal. (Stacking can also be done with each layer being added to the bottom of the stack, as opposed to the top.)

[0188] Referring to Figure 40, each strip 1200, 1202 has front and rear edges 1207, 1208 and opposite side edges 1209a, 1209b. Inlet and outlet flutes of the corrugated sheet/facing sheet combination comprising each strip 1200, 1202 generally extend between the front and rear edges 1207, 1208, and parallel to side edges 1209a, 1209b.

[0189] Still referring to Figure 40. in the media or media pack 1201 being formed, opposite flow faces are indicated at 1210, 1211. The selection of which one of faces 1210, 1211 is the inlet end face and which is the outlet end face, during filtering, is a matter of choice. In some instances, the stacking bead 1206 is positioned adjacent the upstream or inlet face 1211; in others, the opposite is true. The flow faces 1210, 121 1 , extend between opposite side faces 1220, 1221.

[0190] The stacked media configuration or pack 1201 shown being formed in Figure 40, is sometimes referred to herein as a "blocked" stacked media pack. The term "blocked" in this context, is an indication that the arrangement is formed to a rectangular block in which all faces are 90° relative to all adjoining wall faces. For example, in some instances, the stack can be created with each strip 1200 being slightly offset from alignment with an adjacent strip, to create a parallelogram or slanted block shape, with the inlet face and outlet face parallel to one another, but not perpendicular to upper and bottom surfaces.

[0191] In some instances, the media or media pack will be referenced as having a parallelogram shape in any cross-section, meaning that any two opposite side faces extend generally parallel to one another.

[0192] It is noted that a blocked, stacked arrangement corresponding to Figure 40 is described in the prior art of U.S. 5,820,646, incorporated herein by reference. It is also noted that stacked arrangements are described in U.S. 5,772,883; U.S. 5,792,247; U.S. 7,351,270; and U.S. Publication 2004/0187689. Each of these latter references is incorporated herein byreference. It is noted that a stacked arrangement shown in U.S. Publication 2005/0130508 is a slanted stacked arrangement.

[0193] It is also noted that, in some instances, more than one stack can be incorporated into a single media pack. Also, in some instances, the stack can be generated w ith one or more flowfaces that have a recess therein, for example, as shown in U.S. 7,625,419 incorporated herein by reference.

C. Selected Media or Media Pack Arrangements Comprising Multiple Spaced Coils of Fluted Media; Figures 41-43

[0194] Alternate types of media arrangements or packs that involve flutes between opposite ends extending between can be used with selected principles according to the present disclosure. An example of such alternate media arrangement or pack is depicted in Figures 41-43. The media of Figures 41-43 is analogous to one depicted and described in DE 202008017059; and as can sometimes found in arrangements available under the mark “IQORON” from Mann & Hummel. [0195] Referring to Figure 41. the media or media pack is indicated generally at 1250. The media or media pack 1250 comprises a first outer pleated (ridged) media loop 1251 and a second, inner, pleated (ridged) media loop 1252, each with pleat tips (or ridges) extending between opposite flow ends. The view of Figure 41 is toward a media pack (flow) end 1255. The end 1255 depicted, can be an inlet (flow) end or an outlet (flow) end, depending on selected flow direction. For many arrangements, using principles characterized having the media pack 1250 would be configured in a filter cartridge such that end 1255 is an inlet flow end.

[0196] Still referring to Figure 41, the outer pleated (ridged) media loop 1251 is configured in an oval shape, though alternatives are possible. At 1260, a pleat end closure, for example molded in place, is depicted closing ends of the pleats or ridges 1251 at media pack end 1255. [0197] Pleats or ridges 1252 (and the related pleat tips) are positioned surrounded by and spaced from loop 1251, and thus pleated media loop 1252 is also depicted in a somewhat oval configuration. In this instance, ends 1252e of individual pleats or ridges 1252p in a loop 1252 are sealed closed. Also, loop 1252 surrounds a center 1252c that is closed by a center strip 1253 of material, typically molded-in-place.

[0198] During filtering, when end 1255 is an inlet flow end, air enters gap 1265 between the two loops of media 1251, 1252. The air then flows either through loop 1251 or loop 1252, as it moves through the media pack 1250, with filtering.

[0199] In the example depicted, loop 1251 is configured slanting inwardly toward loop 1252, in extension away from end 1255. Also, spacers 1266 are shown supporting a centering ring 1267 that surrounds an end of the loop 1252, for structural integrity.

[0200] In Figure 42, an end 1256 of the cartridge 1250, opposite end 1255 is viewable. Here, an interior of loop 1252 can be seen, surrounding an open gas flow region 1270. When air is directed through cartridge 1250 in a general direction toward end 1256 and away from end 1255, the portion of the air that passes through loop 1252 will enter central region 1270 and exit therefrom at end 1256. Of course, air that has entered media loop 1251 , as show n in Figure 41, during filtering would generally pass around (over) an outer perimeter 1256p of end 1256. [0201] In Figure 43, a schematic cross-sectional view of cartridge 1250 is provided. Selected identified and described features are indicated by like reference numerals.

[0202] It will be understood from a review of Figures 40-43, the above description, that the cartridge 1250 described, is generally a cartridge which has media tips extending in a longitudinal direction between opposite flow ends 1255, 1256.

[0203] In the arrangement of Figures 41-43, the media pack 1250 is depicted with an oval, in particular racetrack, shaped perimeter. It is depicted in this manner since the air filter cartridges, in many examples below, also have an oval or racetrack shaped configuration.

However, the principles can be embodied in a variety of alternate peripheral shapes.

D. Other Media Variations, Figures 44-49

[0204] Herein, in Figures 44-49, some schematic, fragmentary, cross-sectional views are provided of still further alternate variations of media types that can be used in selected applications of the principles characterized herein. Certain examples are described in PCT Publication WO 2016/077377, owned by the Assignee of the present disclosure, Donaldson Company, Inc. In general, each of the arrangements of Figures 44-49 represents a media type that can be stacked or coiled into an arrangement that has opposite inlet and outlet flow ends (or faces), with straight through flow.

[0205] In Figure 44, an example media arrangement 1301 from PCT Publication WO 2016/077377 is depicted, in which an embossed sheet 1302 is secured to a non-embossed sheet 1303, then stacked and coiled into a media pack, with seals along opposite edges of the type previously described for Figure 34 herein.

[0206] In Figure 45, an alternate example media pack 1310 from PCT Publication WO 2016/077377 is depicted, in which a first embossed sheet 1311 is secured to a second embossed sheet 1312 and then formed into a stacked or coiled media pack arrangement, having edge seals generally in accordance with Figure 34 herein.

[0207] Edge seals can be conducted in either the upstream end or the downstream end, or in some instances, both. Especially when the media is likely to encounter chemical material during filtering, it may be desirable to avoid a typical adhesive or sealant.

[0208] In Figure 46, a cross-section is depicted in which the fluted sheet X has various embossments on it for engagement with the facing sheet Y. Again, these can be separate, or sections of the same media sheet.

[0209] In Figure 47, a schematic depiction of such an arrangement between the fluted sheet X and facing sheet Y is also shown.

[0210] In Figure 48, a still further variation of such a principle is shown between a fluted sheet X and a facing sheet Y. These are meant to help understand how a wide variety⁷ of approaches are possible.

[0211] In Figure 49, still another possible variation in fluted sheet X and facing sheet Y is shown. [0212] In Figures 50 and 51, an example media arrangement 6401 is depicted, in which a fluted sheet 6402 is secured to a facing sheet 6403. The facing sheet 6403 may be a flat sheet. The media arrangement 6401 can then be stacked or coiled into a media pack, with seals along opposite edges of the type previously described for Figure 34 herein. In the embodiment shown, flutes 6404 of fluted sheet 6402 have an undulating ridgeline including a series of peaks 6405 and saddles 6406. The peaks 6405 of adjacent flutes 6404 can be either aligned as shown in Figures 50 and 51, or offset. Further the peak height and/or density’ can increase, decrease, or remain constant along the length of the flutes 6404. The ratio of the peak flute height to saddle flute height can vary from about 1.5, typically from 1.1 to about 1.

[0213] It is noted that there is no specific requirement that the same media be used for the fluted sheet section and the facing sheet section. A different media can be desirable in each, to obtain different effects. For example, one may be a cellulose media, while the other is a media containing some non-cellulose fiber. They may be provided with different porosity or different structural characteristics, to achieve desired results.

[0214] A variety of materials can be used. For example, the fluted sheet section or the facing sheet section can include a cellulose material, synthetic material, or a mixture thereof. In some embodiments, one of the fluted sheet section and the facing sheet section includes a cellulose material and the other of the fluted sheet section and facing sheet section includes a synthetic material.

[0215] Synthetic matenal(s) can include polymenc fibers, such as polyolefin, polyamide, polyester, polyvinyl chloride, polyvinyl alcohol (of various degrees of hydrolysis), and polyvinyl acetate fibers. Suitable synthetic fibers include, for example, polyethylene terephthalate, polyethylene, polypropylene, nylon, and rayon fibers. Other suitable synthetic fibers include those made from thermoplastic polymers, cellulosic and other fibers coated with thermoplastic polymers, and multi-component fibers in which at least one of the components includes a thermoplastic polymer. Single and multi-component fibers can be manufactured from polyester, polyethylene, polypropylene, and other conventional thermoplastic fibrous materials.

[0216] The examples of Figures 44-50, are meant to indicate generally that a variety alternate media packs can be used in accordance with the principles herein. Attention is also directed to PCT Publication WO 2016/077377, incorporated herein by reference, with respect to the general principles of construction and application of some alternates media types. E, Additional Media Pack Arrangements Including Pleated Media

With Flutes; Figures 52-55

[0217] Additional examples of alternative types of media arrangements or packs that involve filtration media having flutes extending between opposite ends or flow faces in a straight through flow configuration are depicted in Figures 52-55. The flutes can be considered inlet flutes when they are arranged to receive dirty air via an inlet flow face, and they can be considered outlet flutes when they are arranged to permit filtered air to flow out via an outlet flow face.

[0218] The filtration media 6502 depicted in Figures 52-54, which is analogous to ones depicted in U.S. 8.479,924 and U.S. 9,919.256 assigned to Mann+Hummel GmbH, is illustrated in an arrangement that shows how the filtration media 6502 can be formed into a media pack arrangement 6504.

[0219] The media pack arrangement 6504 can be considered as having relatively long or deep pleats from an inlet flow face 6506 to an outlet flow face 6508, and can also have varying pleat depths as illustrated. As the depth of pleats of a media pack increases, there is a tendency of the filtration media to collapse on each other thereby causing masking. Masking is undesirable because masked filtration media tends to no longer be available for filtration thereby decreasing dust holding capacity and flow through the media pack, and also potentially increasing pressure drop across the media pack. In order to reduce masking and to help the filtration media retain its shape, support structures are known to be applied to pleated media. In Figures 53 and 54, support sections or spacers 6510 are provided. It should be appreciated that Figures 53 and 54 are illustrated in a folded configuration 6512 having pleat folds 6514, but are expanded or separated to show how the filtration media 6502 and the support sections or spacers 6510 can be arranged.

[0220] As illustrated in Figures 53 and 54, the filtration media 6502 extends between a first side 6516 and a second side 6518. Although only one support section 6510 is shown on each pleat face 6520, it should be appreciated that multiple support sections 6510 can be arranged along each pleat face 6520 so that when the filtration media 6502 is arranged into a media pack, as illustrated in Figure 55 as media pack 6604, the volume between each of the support sections 6510 can be considered flutes extending between the inlet flow face 6506 and the outlet flow face 6508. The support sections 6510 can be arranged on each flow face 6520 so that opposite support sections 6510 contact or engage each other to help maintain the media pack shape while also limiting the amount of filtration media that would be contacted by the support sections 6510, as illustrated in Figure 44. Furthermore, by providing that the support sections 6510 have adhesive properties, the support sections 6510 can be provided so that opposing support sections 6510 can adhere to each other when the filtration media 6502 is arranged into the media pack 6504.

[0221] The support sections 6510 can be arranged in a tapered configuration where support sections 6510 have a cross section at an interior fold 6522 and wherein the cross section increases toward an exterior fold 6524. In this context, the phrase ‘'interior fold’’ refers to the side of the media that forms an acute angle, and the phrase “exterior fold” refers to the side of the media that forms an obtuse angle when the media is arranged into a media pack. Furthermore, the reference to changing the cross section of the support sections 6510 can refer to one or both of the height that the support section extends away from the media to which it is adhered and also to the width along the mediate which it is adhered to in a direction toward or away from other support sections across adjacent flutes. Changing the shape of the support sections 6510 can help maintain the shape of the media pack and the resulting flutes, and can help reduce the amount of media that would otherwise be contacted by the support sections 6510 if they were not arranged in a tapered configuration. In addition, the support sections 6510 can be arranged in a non-tapered configuration. As illustrated in Figure 44, the support sections 6510 can be provided so that they extend over the exterior folds 6524, although it is not necessary’ for the support sections 6510 to extend over the exterior folds. In addition, it is not necessary for the support sections 6510 to extend into the interior folds 6522, although, if desired, the support sections 6510 can be provided so that they extend into the interior folds 6522.

[0222] The support sections 6510 can be applied to the filtration media 6502 as adhesive extruded onto the filtration media 6502 where the adhesive forms the support sections 6510. Before the adhesive has a chance to fully cure, the filtration media 6502 can be folded into the media pack arrangement 6504, which may or may not have varying pleat depths. By forming the media pack arrangement 6504 before the adhesive has fully cured, the opposing support sections 6510 can become bonded or adhered to each other thereby forming flutes extending between the inlet flow face 6506 and the outlet flow face 6508.

[0223] It should be appreciated that the filtration media 6502 can be provided with deformation, such as corrugations, extending across the media. The direction of deformation, such as corrugation, can be parallel or perpendicular to the pleat fold direction.

[0224] The filtration media 6602 depicted in Figure 55 is analogous to filtration media depicted in U.S. Publication 2018/0207566, assigned to Champion Laboratories, Inc., as another example of a media pack arrangement 6604 having inlet and outlet flutes in a straight through flow arrangement.

[0225] The filtration media pack arrangement 6604 can be formed by folding the filtration media 6602 to form an inlet flow face 6606 and an outlet flow face 6608. Pleat tips 6610 form the inlet flow face 6606, and pleat tips 6612 form the outlet flow face 6608. Adhesive beads 6616 and 6618, which may be continuous or discontinuous, extend along the filtration media 6602 in multiple lines across the filtration media 6602 from a media first side 6620 to a media second side 6622. The adhesive beads 6616 and 6618 along the media first side 6620 and along the media second side 6620 can be thickened, if desired, and can be arranged to provide an edge seal along the media first side 6620 and the media second side 6622. By providing that the adhesive beads 6616 and 6618 adhere to each other as the filtration media 6602 is folded, inlet flutes 6630 and outlet flutes 6632 can be formed in the straight through media pack arrangement 6604.

[0226] A similar type of filtration media pack arrangement is commercially available under the name Enduracube from Baldwin Filters. Inc. The filtration media pack available under the name Enduracube from Baldwin Filters, Inc. is arranged in a pleated configuration forming inlet flutes and outlet flutes extending between an inlet flow face and an outlet flow face.

F, Still Further Media Types

[0227] Many of the techniques characterized herein will preferably be applied when the media is oriented for filtering between opposite flow ends of the cartridge is media having flutes or pleat tips that extend in a direction between those opposite ends. However, alternatives are possible. The techniques characterized herein with respect to seal arrangement definition can be applied in filter cartridges that have opposite flow ends, with media positioned to filter fluid flow between those ends, even when the media does not include flutes or pleat tips extending in a direction between those ends. The media, for example, can be depth media, can be pleated in an alternate direction, or it can be a non-pleated material.

[0228] It is indeed the case, however, that the techniques characterized herein are particularly advantageous for use with cartridges that are relatively deep in extension between flow ends, usually at least 100mm, typically at least 150mm , often at least 200 mm, sometimes at least 250mm, and in some instances 300mm or more, and are configured for large loading volume during use. These ty pes of systems will ty pically be ones in which the media is configured with pleat tips or flutes extending in a direction between opposite flow ends. [0229] It is also noted that while the techniques described herein were typically developed for advantageous application and arrangements involving media packs with straight through flow configurations, the techniques can be applied to advantage in other systems. For example, the techniques can be applied when the cartridge comprises media surrounding a central interior, in which the cartridge has an open end. Such arrangements can involve “forward flow” in which air to be filtered enters the central open interior by passage through the media, and the exits through the open end; or, with reverse flow in which air to be filtered enters the open end and then turns and passes through the media. A variety of such arrangements are possible, including pleated media and alternate ty pes of media. Configurations usable would include cylindrical and conical, among others.

Aspects

[0230] The present disclosure includes various aspects that may be claimed in the future. The following aspects are intended to highlight certain features without limiting the scope of protection. It should be understood that any of the following aspects may be claimed in a patent application claiming priority⁷ to the present disclosure, either alone or in combination with other aspects. Further, the following aspects may be modified or combined in any suitable manner apparent to one skilled in the art in light of the teachings herein. Features which are described in the context of separate aspects and embodiments of the disclosure may be used together and/or be interchangeable. Similarly, features described in the context of a single embodiment may also be provided separately or in any suitable subcombination. The aspects are numbered for convenience only and should not be construed as requiring a particular order or limiting the scope of what may be claimed. In various aspects, an air cleaner housing and related filter cartridges are provided that include features and components as described in one or more of the following aspects. The aspects may be combined or modified in ways apparent to those skilled in the art based on the teachings herein. While specific materials, dimensions, and configurations are described for certain aspects, these are exemplary only and other materials, dimensions and configurations may be used within the scope of the disclosure.

[0231] Aspect 1: An air filter cartridge for use within a housing assembly of an air cleaner, and including: a media pack having filter media extending from a first end to a second end; and a first end cap arranged at the first end of the media pack, the first end cap presenting an inner radial side defining a seal surface having a generally polygonal shape formed by a plurality of flat sides and adjoining comer portions, the first end cap having a first cross-sectional thickness extending through the flat sides that is greater than a second cross-sectional thickness extending through the comer portions.

[0232] Aspect 2: The air filter cartridge according to Aspect 1, or any of Aspects 3 to 26, wherein the first end cap is formed as a single, monolithic component.

[0233] Aspect 3: The air filter cartridge according to Aspect 1, or any of Aspects 2 and 4 to 26, wherein the first end cap includes a plurality of support members at least partially defining the first cross-sectional thickness.

[0234] Aspect 4: The air filter cartridge according to Aspect 1, or any of Aspects 2 to 3 and

5 to 26, wherein a distal axial end of the filter cartridge is defined by the end cap at a location that is radially aligned with the seal surface flat sides.

[0235] Aspect 5: The air filter cartridge according to Aspect 1, or any of Aspects 2 to 4 and

6 to 26, wherein the first end cap includes a seal member defining the inner radial side and defining an outer radial side, wherein the seal member is unsupported on the outer radial side at locations radially aligned with the seal surface comer portions.

[0236] Aspect 6: The air filter cartridge according to Aspect 1, or any of Aspects 2 to 5 and

7 to 26, wherein the first end cap includes a seal member defining the inner radial side and wherein the seal member has a constant cross-sectional thickness.

[0237] Aspect 7: The air filter cartridge according to Aspect 1, or any of Aspects 2 to 6 and

8 to 26, wherein the first end cap includes a seal member having a radial inner side defining the seal surface and a radial outer side defining a plurality of flat sides and adjoining inwardly extending comer portions.

[0238] Aspect 8: The air filter cartridge according to Aspect 7, or any of Aspects 1 to 6 and 8 to 26, wherein the first end cap includes a support band surrounding the radial outer side of the seal member.

[0239] Aspect 9: The air filter cartridge according to Aspect 1, or any of Aspects 2 to 8 and 10 to 26, wherein the seal surface is formed by a plurality of lip seals.

[0240] Aspect 10: An air filter cartridge for use within a housing assembly of an air cleaner, wherein the filter cartridge includes a media pack having filter media extending from a first end to a second end; a first end cap arranged at the first end of the media pack, the first end cap defining a first seal surface; and a second end cap removably sealed to the first end cap, the second end cap including an axial extension defining a second seal surface sealed against the first seal surface, the second end cap defining a third seal surface having a generally polygonal shape formed by a plurality of flat sides and adjoining comer portions. [0241] Aspect 11: The air filter cartridge according to Aspect 10, or any of Aspects 1 to 9 and 12 to 26. wherein the second end cap includes a support member defining the second seal surface and a seal member defining the third seal surface.

[0242] Aspect 12: The air filter cartridge according to Aspect 10, or any of Aspects 1 to 9, 11, and 13 to 26, wherein the third seal surface is a radially inward facing seal surface.

[0243] Aspect 13: The air filter cartridge according to Aspect 10, or any of Aspects 1 to 9, 11-12, and 14 to 26, the third seal surface is a radially outward facing seal surface.

[0244] Aspect 14: The air filter cartridge according to Aspect 10, characterized in that the third seal surface is formed by a polyurethane seal member.

[0245] Aspect 15: The air filter cartridge according to Aspect 10, or any of Aspects 1 to 9, 11-14, and 16 to 26, the third seal surface is formed by a plurality of lip seals.

[0246] Aspect 16: An air filter cartridge for use within a housing assembly of an air cleaner, characterized in that: the filter cartridge includes a media pack having filter media extending from a first end to a second end; and a first end cap arranged at the first end of the media pack, the first end cap presenting an outer radial side defining a seal surface having a generally polygonal shape formed by a plurality of flat sides and adjoining comer portions, the first end cap presenting an undercut surface located between the seal surface and the first end of the media pack.

[0247] Aspect 17: The air filter cartridge according to Aspect 16, or any of Aspects 1 to 15 and 18 to 26. the first end cap includes a seal member having an outer radial side defining the seal surface and includes a plurality of support members radially supporting an inner radial side of the seal member.

[0248] Aspect 18: The air filter cartridge according to Aspect 16. or any of Aspects 1 to 15, 11-17, and 19 to 26, the media pack includes pleated media.

[0249] Aspect 19: An air filter cartridge for use within a housing assembly of an air cleaner and including: a media pack having filter media extending from a first end to a second end; and a seal arrangement operably arranged on the media pack and presenting an outer radial side defining a seal surface having a generally polygonal shape formed by a plurality of flat sides and adjoining comer portions, wherein the seal surface is formed by at least one lip seal.

[0250] Aspect 20: The air filter cartridge according to Aspect 19, or any of Aspects 1 to 18 and 21 to 26, the plurality of lip seals includes one to four lip seals.

[0251] Aspect 21: The air filter cartridge according to Aspect 19. or any of Aspects 1 to 18, and 22 to 26, further including a support arrangement, wherein the plurality of lip seals are injection molded onto an outer radial surface of the support arrangement. [0252] Aspect 22: The air filter cartridge according to Aspect 19. or any of Aspects 1 to 18, and 19 to 21. and 23 to 26, wherein the plurality of lip seals are formed from a thermoplastic elastomer material.

[0253] Aspect 23: The air filter cartridge according to Aspect 19, or any of Aspects 1 to 18, and 19 to 22, and 24 to 26, wherein the seal arrangement circumscribes the media pack between the first and second ends.

[0254] Aspect 24: The air filter cartridge according to Aspect 19, or any of Aspects 1 to 18, and 19 to 23, and 25 to 26, wherein the seal arrangement is spaced from the media pack.

[0255] Aspect 25: The air filter cartridge according to Aspect 19, or any of Aspects 1 to 18, and 19 to 24, and 26. wherein the media pack has a cylindrically shaped outer perimeter.

[0256] Aspect 26: The air filter cartridge according to Aspect 21. or any of Aspects 1 to 20. and 22 to 25, wherein the support arrangement includes a plurality of reinforcement members located on a radial inner side of the seal member and spaced from an outer perimeter of the media pack.

Summary

[0257] The principles described herein can be applied in a variety of filter assemblies. Examples described in which the principles applied to (air) gas filter assemblies. Examples are described include air filters, for example, air filters used for treating engine intake airflows. The principles can be applied to a variety of alternate gas filtration arrangements, in some instances even with liquid filter assemblies. Again, 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.

Claims

What is claimed is:

1 . An air filter cartridge for use within a housing assembly of an air cleaner, the filter cartridge comprising: a) a media pack including filter media extending from a first end to a second end; and b) a first end cap arranged at the first end of the media pack, the first end cap presenting an inner radial side defining a seal surface having a generally polygonal shape formed by a plurality of flat sides and adjoining comer portions, the first end cap having a first cross-sectional thickness extending through the flat sides that is greater than a second cross-sectional thickness extending through the comer portions.

2. The air filter cartridge of claim 1, wherein the first end cap is formed as a single, monolithic component.

3. The air filter cartridge of claim 1, wherein the first end cap includes a plurality of support members at least partially defining the first cross-sectional thickness.

4. The air filter cartridge of claim 1, wherein a distal axial end of the filter cartridge is defined by the end cap at a location that is radially aligned with the seal surface flat sides.

5. The air filter cartridge of claim 1, wherein the first end cap includes a seal member defining the inner radial side and defining an outer radial side, wherein the seal member is unsupported on the outer radial side at locations radially aligned with the seal surface comer portions.

6. The air filter cartridge of claim 1, wherein the first end cap includes a seal member defining the inner radial side and wherein the seal member has a constant cross- sectional thickness.

7. The air filter cartridge of claim 1, wherein the first end cap includes a seal member having a radial inner side defining the seal surface and a radial outer side defining a plurality of flat sides and adjoining inwardly extending comer portions.

8. The air filter cartridge of claim 7, wherein the first end cap includes a support band surrounding the radial outer side of the seal member.

9. The air filter cartridge of claim 1, wherein the seal surface is formed by a plurality of lip seals.

10. An air filter cartridge for use within a housing assembly of an air cleaner, the filter cartridge comprising: a) a media pack including filter media extending from a first end to a second end; b) a first end cap arranged at the first end of the media pack, the first end cap defining a first seal surface; and c) a second end cap removably sealed to the first end cap, the second end cap including an axial extension defining a second seal surface sealed against the first seal surface, the second end cap defining a third seal surface having a generally polygonal shape formed by a plurality of flat sides and adjoining comer portions.

11. The air filter cartridge of claim 10, wherein the second end cap includes a support member defining the second seal surface and a seal member defining the third seal surface.

12. The air filter cartridge of claim 10, wherein the third seal surface is a radially inward facing seal surface.

13. The air filter cartridge of claim 10. wherein the third seal surface is a radially outward facing seal surface.

14. The air filter cartridge of claim 10, wherein the third seal surface is formed by a polyurethane seal member.

15. The air filter cartridge of claim 10. wherein the third seal surface is formed by a plurality of lip seals.

16. An air filter cartridge for use within a housing assembly of an air cleaner, the filter cartridge comprising: a) a media pack including filter media extending from a first end to a second end; and b) a first end cap arranged at the first end of the media pack, the first end cap presenting an outer radial side defining a seal surface having a generally polygonal shape formed by a plurality of flat sides and adjoining comer portions, the first end cap presenting an undercut surface located between the seal surface and the first end of the media pack.

17. The air filter cartridge of claim 16. wherein the first end cap includes a seal member having an outer radial side defining the seal surface and includes a plurality of support members radially supporting an inner radial side of the seal member.

18. The air filter cartridge of claim 16, wherein the media pack includes pleated media.

19. An air filter cartridge for use within a housing assembly of an air cleaner, the filter cartridge comprising: a) a media pack including filter media extending from a first end to a second end; and b) a seal arrangement operably arranged on the media pack and presenting an outer radial side defining a seal surface having a generally polygonal shape formed by a plurality of flat sides and adjoining comer portions, wherein the seal surface is formed by at least one lip seal.

20. The air filter cartridge of claim 19, wherein the at least one lip seal includes one to four lip seals.

21. The air filter cartridge of claim 19. further including a support arrangement, wherein the at least one lip seal is injection molded onto an outer radial surface of the support arrangement.

22. The air filter cartridge of claim 21. wherein the at least one lip seal is formed from a thermoplastic elastomer material.

23. The air filter cartridge of claim 19, wherein the seal arrangement circumscribes the media pack between the first and second ends.

24. The air filter cartridge of claim 19, wherein the seal arrangement is spaced from the media pack.

25. The air filter cartridge of claim 19. wherein the media pack has a cylindrically shaped outer perimeter.

26. The air filter cartridge of claim 21, wherein the support arrangement includes a plurality of reinforcement members located on a radial inner side of the seal member and spaced from an outer perimeter of the media pack.