USRE45588E1 - Air cleaner arrangements; serviceable filter elements; and, methods - Google Patents

Abstract

An air cleaner arrangement or assembly is provided. The air cleaner arrangement includes a serviceable filter cartridge. The air cleaner assembly also includes an arrangement for positioning the filter cartridge into a preferred, sealing, orientation and for securing the filter cartridge in that location. Preferred serviceable filter cartridges are provided, as well as methods of assembly and use.

Description

The present application is a continuation application of U.S. Ser. No. 10/589,519, filed May 8, 2007 now U.S. Pat. No. 7,682,416 as a U.S. National Stage application of PCT/US2005/005104, filed Feb. 16, 2005, which claims priority to U.S. Ser. No. 60/545,401, filed Feb. 17, 2004. A claim of priority to each of U.S. Ser. No. 10/589,519; PCT/US2005/005104; and 60/545,401 is made to the extent appropriate. Also, each of U.S. Ser. No. 10/589,519; PCT/US2005/005104; and, 60/545,401 is incorporated herein by reference, in its entirety.

The present application is a reissue application U.S. Pat. No. 7,972,405 issued on Jul. 5, 2011, which issued from U.S. Ser. No. 12/704,909 filed on Feb. 12, 2010, which is a continuation of U.S. Ser. No. 10/589,519, filed May 8, 2007 now U.S. Pat. No. 7,682,416 as a U.S. National Stage application of PCT/US2005/005104, filed Feb. 16, 2005, which claims priority to U.S. Ser. No. 60/545,401, filed Feb. 17, 2004. A claim of priority to each of U.S. Ser. No. 12/704,909; U.S. Ser. No. 10/589,519; PCT/US2005/005104; and U.S. Ser. No. 60/545,401 is made to the extent appropriate. Also, U.S. Ser. No. 12/704,909; U.S. Ser. No. 10/589,519; PCT/US2005/005104; and U.S. Ser. No. 60/545,401 are incorporated herein by reference, in their entirety.

TECHNICAL FIELD

This disclosure relates to air cleaners and to components for air cleaners. This disclosure particularly concerns air cleaners of a type useable for cleaning intake air for engines. Methods of assembly and use are also provided.

BACKGROUND

Air cleaners are needed for a variety of applications, for example to provide cleaning of engine intake air for internal combustion engines. A wide variety of types of air cleaner arrangements and filter materials are known.

One known filter material, is filter media configured in a z-arrangement. Z-filter media generally comprises a corrugated or fluted media sheet secured to a facing sheet. The media is arranged to form a set of longitudinal flutes or air flow channels on one side of the corrugated or fluted media, and another set of flow channels on an opposite side of the corrugated or fluted media. In operation, flutes of one set of flutes are designated as inlet flutes, in which individual inlet flutes are left open at an inlet end or side of the media, and are sealed, folded or otherwise closed at an outlet end or side of the media. Analogously, the flutes of a second set of flutes are generally designated as outlet flutes, are sealed, folded or otherwise closed at the inlet end or side of the filter, and are left open at the outlet end or side of the filter. In operation, air passes into one flow face of the air filter construction, by passage into the open inlet flutes at an upstream end of the element. The air cannot flow out of the closed ends of these inlet flutes, so it must pass through the filter media into the outlet flutes. The filtered air then passes outwardly from an exit end of the filter element, through the open ends of the outlet flutes.

A variety of z-filter constructions are known; including, for example, the ones described in U.S. Pat. Nos. 5,820,646; 5,792,247; 6,190,432; and, 6,350,291; PCTPublication WO 97/40918; U.S. provisional application 60/395,009 filed 10 Jul. 2002; and the PCT Application US 03/02799 filed Jan. 31, 2003 and claiming priority from U.S. Provisional 60/395,009; the complete disclosures of all eight references above being incorporated herein by reference. These types of media (among others) can be used in arrangements of the types described herein.

Z-filter media has been characterized as useable in coiled configurations, see for example U.S. Pat. No. 6,350,291; or in stacks of sheets of z-filter media, see for example FIG. 26 of U.S. Pat. No. 5,820,646.

SUMMARY OF THE DISCLOSURE

In the present disclosure, unique features of air filter cartridge arrangements are described and shown. In addition, unique air cleaner arrangement or features, for receiving and mounting the filter cartridge arrangements are provided.

With the various features shown and described, or selected combinations of them, unique and convenient filter cartridges and air cleaner assemblies can be made.

The disclosure also concerns methods of installing air filter cartridges, and methods of removing them. In addition, from the descriptions provided, methods of assembling preferred filter cartridges and preferred air cleaner assemblies will be apparent.

The current disclosure concerns certain preferred arrangements for utilization of z-filter media constructions. Related, by structure, arrangements are described in the U.S. utility application entitled “Air Cleaner Arrangements, Serviceable Filter Elements; and, Methods” filed Feb. 10, 2004 by the inventors Randall Allen Engelland, Thomas Richard Olson, Gary Ray Gillingham, Jim C. Rothman, and Richard Lawrence Suydam, under Express Mail #EL 976593878 US. The complete disclosure of the Feb. 10, 2004 Express Mail #EL 976593878 US filing is incorporated herein by reference. Also, the current disclosure is related, by structure, to the following two U.S. Provisional applications: U.S. 60/446,804 filed Feb. 11, 2003; and 60/457,255, filed Mar. 25, 2003. The complete disclosure of these two provisional applications are incorporated herein by reference.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an engine system including an air cleaner arrangement according to the present disclosure.

FIG. 2 is an outlet end perspective view of an air cleaner arrangement according to the present disclosure.

FIG. 3 is an exploded, inlet end, perspective view of the air cleaner arrangement shown inFIG. 2.

FIG. 4 is an outlet end perspective view of a filter cartridge useable in the air cleaner arrangement ofFIG. 3.

FIG. 5 is a perspective view of an access cover and biasing arrangement component of the air cleaner arrangement ofFIGS. 2 and 3.

FIG. 6 is an outlet end perspective view of an air cleaner housing for the air cleaner ofFIGS. 2 and 3, depicted without a filter cartridge component positioned therein.

FIG. 7 is a schematic view of z-filter media utilizable in arrangements according toFIGS. 2-6.

FIG. 8 is a schematic view of a stacked z-filter media arrangement utilizing the mediaFIG. 7.

FIG. 9 is a schematic representation of a coiled z-filter media arrangement utilizing the media ofFIG. 7.

FIG. 10 is an enlarged, fragmentary, cross-sectional view of an alternate seal member to the arrangement ofFIGS. 2-6.

FIG. 11 is a perspective view of a rigid seal structure mountable on a housing and usable with a seal member of the element ofFIG. 10.

DETAILED DESCRIPTIONI. FIGS.1-9

The present disclosure concerns certain air cleaners which use filter elements having a straight through flow design. By the term “straight through flow design,” it is meant that air enters a serviceable filter cartridge within the air cleaner, along one (inlet) face, and filtered air exits the filter cartridge from an opposite, second (outlet) face. That is, the inlet and outlet flow paths for the serviceable filter cartridge are generally in the same direction.

As indicated, air cleaners of the type concern that the present disclosure, include serviceable filter elements or cartridges. The term “serviceable filter element or cartridge”, and variants thereof, in this context, is meant to refer to a filter element or cartridge that can be removed from the remainder of the air cleaner and be replaced therein. Typically the filter cartridge of an air cleaner for intake air of combustion engines needs to be serviceable, since periodically the filter cartridge will become occluded, and must be removed and be replaced.

Air cleaners and serviceable filter cartridges of the general type characterized herein, can be used in a variety of arrangements. Typical applications include as air cleaners for internal combustion engines. The air cleaner assemblies and cartridges can be sized and configured for a wide variety of engine applications. Herein, a particular application, involving a large diesel engine having a turbocharger upstream of the air cleaner assembly, is described as an example. However, the principles disclosed herein can be applied in a wide variety of alternate applications, including for example, in air cleaners in systems that do not have a turbocharger upstream of the air cleaner.

Thereference numeral1,FIG. 1, generally indicates an engine system. Theengine system1 includes aninternal combustion engine2, such as a diesel engine, with anair intake system3, including, among other things, a turbocharger and aftercooler arrangement4 and an air cleaner or aircleaner assembly5. For the particular arrangement shown, the turbocharger and aftercooler arrangement4 is positioned upstream of theair cleaner5. Thus, after passage through the turbocharger and after cooler4, air is forced through theair cleaner5 and into the air intake for thediesel engine2. Large diesel engines rated at up to 750-horse power used with military vehicles, would be some typical examples of such an arrangement. The present air cleaner assembly can be used with such equipment, and thus can be operated with an internal pressure, upstream of the filter media, of (for example) 45 psi. However, the techniques can be applied in other systems also, including ones that do not have a turbocharger upstream from the air cleaner.

InFIG. 2, an air cleaner arrangement orassembly5 according to the present disclosure is provided in perspective view. The orientation of the assembly inFIG. 2, is such that the viewer can see an exit or outlet end of the air cleaner, and an adjacent side.

Referring toFIG. 2, anouter housing10 for theair cleaner5 is depicted. Thehousing10 is shown with removable service panel oraccess panel11 mounted thereon. Thehousing10 operates as aduct13 through which, in use, air to be filtered or cleaned flows. Specifically, air to be filtered entersduct13 through inlet end oropening15 and, after passage through an internally received, serviceable,filter cartridge30, the air exits theduct13 through opposite outlet end oropening16. In general, air cleaner operation involves passing the air, as it moves from inlet end or opening15 tooutlet opening16, through afilter media pack31 contained in the removable and replaceable, i.e. serviceable,filter cartridge30.

The principles disclosed herein can be applied in a variety of shapes and sizes of housings. Theparticular housing10 shown, is meant to be an example only. However, the generally rectangular (in cross-section perpendicular to air flow) configuration depicted is preferred, and the principles disclosed are particularly well adapted for application in a housing of such a preferred configuration. Of course, the preferred air cleaner and filter cartridge configurations shown are, in more general terms, non-circular (in cross-section) configurations.

The particular housing10 (FIGS. 2 and 3) depicted has aside wall18 definingopposite sides19,20, opposite top andbottom panels22,23, and opposite inlet and outlet ends25,26 respectively.Top22 generally corresponds to a portion of the side wall which is openable by removal of the access orservice cover11. Thewalls19,20,22,23,25 and26 define an interior27 of thehousing10, into whichserviceable filter cartridge30 is positioned, in use.

InFIG. 3 theair cleaner5 is depicted in exploded view withaccess cover11 removed. Thefilter cartridge30 includes an air inlet end orface32 and an opposite air outlet end orface33. Thefilter cartridge30 has a straight through flow design, meaning that it has opposite inlet and outlet flow faces32,33, respectively with (in use) air flowing therebetween. That is, the direction of inlet flow into thefilter cartridge30 and the direction of outlet flow from thefilter cartridge30 are generally the same. Referring toFIG. 3, it is noted thatinlet15 is positioned in a different plane thanoutlet16. Thus for theparticular arrangement5 depicted, the inlet air flow flows throughinlet15 intohousing10 in a different cross-sectional plane than it leaves thehousing10 throughoutlet16. However, with respect to flow through thefilter cartridge30, the opposite flow faces32,33, for the preferred arrangement shown, are parallel to one another and the flow through thecartridge30 is generally straight. It is noted that a variety of alternatives to the particular configuration shown, can be applied still using principles according to the present disclosure.

Thefilter cartridge30 includesfilter media31. Thefilter media31 depicted, is of the z-filter type, comprising corrugated or fluted media secured to a non-fluted facing sheet. The facing sheet can be corrugated or non-corrugated. Such media can be provided in a variety of configurations including: as coiled continuous sheet configurations as shown schematically inFIG. 9 at300; or, as stacked constructions of individual sheets shown schematically inFIG. 8 at350 and described with respect to FIG. 26 of U.S. Pat. No. 5,820,646 incorporated herein by reference. Either one of these two types of z-filter media arrangements can be used to provide the configuration generally depicted inFIGS. 2-6. Indeed, the drawings ofFIGS. 2-6 are schematic and are not meant to necessarily depict any specific z-filter media arrangement.

It is anticipated that in a typical use such asFIGS. 2-6, a coiled configuration of z-filter media, having a perimeter shape somewhat similar toelement300,FIG. 9, will be preferable; although relative side dimensions may be modified. That is, a preferred approach would use a continuous strip of fluted or corrugated media secured to a non-fluted (preferably non-corrugated) facing media, coiled into the rectangular or square configuration shown, having: a first pair of opposite, generally parallel, sides; a second pair of opposite, generally, parallel sides; and four rounded corners. One useable type of z-filter media for this is depicted in the schematic ofFIG. 7, discussed below.

Referring toFIGS. 3 and 4, thepreferred filter cartridge30 includes filter cartridge sidewall construction (or sheath construction)40 positioned surrounding themedia31. The sidewall orsheath construction40, is preferably impermeable, although alternatives are possible. The term “impermeable” in this context, is meant to refer to a filter cartridge sidewall orsheath construction40 that comprises a solid, non-permeable, plastic or metal component. That is, while the air can pass frominlet end32 to exitend33, and thus through the length of the sidewall orsheath construction40 between its open ends, in preferred constructions the air cannot pass directly through aside wall40a of the sidewall orsheath construction40.

The sidewall orsheath construction40 can be provided in a variety of manners and by a variety of constructions. For example, it can comprise a single piece molded plastic or cast metal construction, a multi-piece clamshell construction of plastic or metal components, or a sheet or sheath of material such as aluminum wrapped around themedia31.

The sidewall orsheath construction40 can be permanently secured to themedia31, if desired. This is preferred for the application shown. Alternatively themedia31 can be removably positioned within thesheath construction40. The term “permanently secured” in this context, is meant to refer to acartridge30 in which the sidewall orsheath construction40 and themedia pack31 are generally secured to one another and are not separated during a servicing operation. Typically securement would be with an adhesive or seal material, as appropriate. If themedia pack31 is removably positioned within the sidewall andsheath construction40, it is expected that during a servicing operation, the sidewall orsheath construction40 would be retained and be reused, but themedia pack31 would be replaced.

Referring toFIG. 4, at air exit oroutlet end33, theserviceable filter cartridge30 includes a first, primary,seal arrangement45. The first orprimary seal arrangement45 includes aseal member45a (shown in fragmentary) positioned onframework46 to provide a seal (i.e., a housing seal) upon appropriate engagement with a portion of thehousing10. Typically, theseal arrangement45 comprises a seal member formed from rubber like material, such as foamed polyurethane, although alternatives are possible. In typical preferred applications, the seal member is configured to axially engage a sealing surface of thehousing10 at or adjacent an inside surface of theoutlet end wall26,FIG. 2, although alternatives are possible.

A variety of specific configurations and orientations for the seal member can be used. An example would be mounting the seal member on a portion of theimpermeable sheath construction40 itself, for example on a flange integral with a remainder of thesheath construction40. Another example would be mounting theseal member45a on aframe piece51, as shown, which is itself adhered to, welded to or otherwise secured to, a remainder of theimpermeable sheath construction40. A third example would be mounting the seal member directly on themedia31; and a fourth would be mounting the seal member on a frame which is attached directly to themedia31 and not to thesheath40.

Referring toFIG. 4, theparticular filter cartridge30 depicted is configured for theseal member45a secured to thesheath40, in particular secured in agroove46a withinstructure45 on thesheath40. InFIG. 4, theseal member45a is shown in fragmentary view. In use, it would circumscribe theflow face33.

Theseal member45a can be permanently attached to theframework51 or it can be removably secured thereto. An example of permanent attachment, would be a molding of the seal member, for example from a foamed polyurethane material, directly onto theframework46 for theseal arrangement45. Another type of permanent attachment, would be attachment with an adhesive.

If a molding operation is used to secure theseal member45a to theframework51, and an issue is perceived with respect to adherence of the molded seal material to the material of theframework piece51, an arrangement can be made to provide for mechanical interlock. For example, apertures can be placed in a portion of theframework51, allowing the moldable polymer to flow therethrough and provide for mechanical interlock after care or set, or various flange arrangements or other structures can be used to facilitate mechanical interlock.

An example of non-permanent attachment, would be a removable o-ring or similar structure positioned withingroove46.

Referring toFIG. 4, thefilter cartridge30 could be constructed to include a support lattice or framework, for example a grid pattern, positioned withincartridge30 in extension overoutlet face31 of the media. Such grid patterns are known, see for example the U.S. Provisional applications 60/446,804 and 60/457,255 referenced above. Such grid patterns can be used, for example, to stabilize themedia31. Alternatively, the grid pattern can be secured to thehousing10.

Referring toFIG. 3, sealing of thefilter cartridge30 against thehousing10 occurs by driving thecartridge30, in the direction of arrow61 (once thecartridge30 is inside the housing10) into sealing engagement with thehousing10, atoutlet end26. As can be understood from the figures and descriptions herein, this driving or biasing is preferably conducted without rotation of thefilter cartridge30 around a central longitudinal axis projecting therethrough. A preferred biasing andlock mechanism65, discussed below, is provided to effect this motion, although alternatives are possible. (It is noted that for the example shown, the biasingdirection61 is the same as the air flow direction. Alternatives are possible.)

Referring toFIGS. 3 and 4, attention is now directed toprojection arrangement67 positioned spaced from,air exit end33 of thecartridge30. Theprojection arrangement67 shown generally comprises first andsecond projections68 and69 respectively positioned on aside70 ofsheath construction40. Preferably onside71, as mirror images ofprojections68,69, a second pair ofprojections68a,69a are positioned (FIG. 3). Theseprojections68,69 are positioned to be engaged by a portion of the biasing andlock mechanism65 as described below.

For the particular arrangement depicted, theprojections68,69 (68a,69a) are pins generally circular in cross-section, although alternate configurations can be used. It is noted thatpin68 is located closer tooutlet face33 than is pin69 (similarly pin68a is closer tooutlet face33 than ispin69a). Advantage from this will be understood from descriptions below.

Hereinprojections68,69 will sometimes be referred to as having different axial spacing fromend33 orseal arrangement45. The term “axial spacing” in this context is meant to refer to an axial distance from theface33 orseal arrangement45. The indication of “difference,” is simply meant to indicate the two projections,68,69, have a different amount of spacing fromface33 orseal arrangement46. A similar mirror image arrangement would be case forprojections68a,69a.

In addition,projections68,69 are sometimes referenced herein as having different “vertical” spacing. Here reference is meant to the orientation ofFIG. 3 from which, it can be seen, that in typical use,projection69a is belowprojection68a.

The particular number of projections from each side, is not critical. Utilization of two projections fromside70 andside71 is convenient, although alternatives are possible. Indeed in some arrangements a single projection from each side may be used. However, thepreferred arrangement30 includes two spaced pins, as shown.

Preferably the vertical spacing between thepins68 and69 (or68a and69a) on one side, is at least 20% of the length of that associated side of the cartridge, for example pins68 and69 are preferably spaced apart vertically by a distance corresponding to at least 20% of the length ofside70. Most preferably the spacing is at least 30% of the length of the associated side.

Referring toFIG. 3, the preferred biasing andlock mechanism65 includes biasing and lockprojections85,86 attached to accesscover11. Eachprojection85,86 is preferably permanently secured to thepanel11; and, for example, ifpanel11 is molded,projections85,86 can be made integral withpanel11.

Referring toFIG. 5,projection85 includes abase89 and depending biasing andlock blade90; theblade90 extending away fromcover11. Theblade90 has oppositefront edge91 andrear edge92 and atip93.Tip93, for the particular arrangement shown, is curved. Theblade90 is preferably oriented such that it is in a plane generally perpendicular to a cross section of thefilter cartridge30, taken perpendicular to air flow, during use.

In this context, the term “front” in reference to “front edge91” or in an analogous context, is meant to refer to an edge which facesprojections68,69 (or68a,69a) ofcartridge30, during use. The term “rear edge” is meant to refer to an oppositely directed edge.

Rear edge92 is preferably straight (linear) and is preferably directed perpendicularly to a cross section (across air flow direction) ofhousing10.Front edge91, positioned oppositely ofedge92, is preferably contoured and not straight (linear), in this instance havingedge sections91a,91b and91c. For the arrangement shown,sections91a and91c are straight (linear) and generally define lines parallel to one another and substantially parallel to edge92, whereassection91b is a transition section extending betweensections91c and91a;section91b having curved ends to joinsections91a,91c, and a straight center non-parallel to edge92.Section91b can be viewed as a ramp section.Edge section91c is spaced further fromedge92 than isedge section91a. In some instances,sections91a and91c can be angled slightly forwardly, towardend16, in extension upwardly towardbase89, to cause some cam effect.

Blade86 is similarly constructed and is positioned oncover11 as a mirror image toblade85. Thus edge86 includesbase96.Blade97 has opposite edges98 and99 andtip100, withedge98 being preferably straight and perpendicular to air flow, and withedge99 beingopposite edge98 and generally having a contoured shape, in this instance with threesections99a,99b and99c corresponding generally tosections91a,91b, and91c ofblade90, respectively. Theblades85,86 are generally spaced apart from one another a distance such that afilter cartridge30,FIG. 3, can be positioned or fit therebetween, when theaccess cover11 is positioned in thehousing10.

Herein, contoured edges91,99 of theblade90,97 will sometimes be referred to as the filter cartridge engagement edges. The filter cartridge engagement edges91,99 will sometimes be characterized as having a shape which allows for a biasing action, to move thecartridge30 toward a seal position, as thecover11 is put in position. The preferred shape shown tends to increase the biasing, as thecover11 is positioned. This shape, sometimes referenced as a contoured shape, generally refers to a non-linear overall shape which will bias, axially, thecartridge30 as the blade is slid along a portion of thecartridge30. Preferably the contourededges91,99 include upper sections (91c,99c) which are positioned axially toward theoutlet end33, andseal arrangement45, at least 0.25 cm further than other, lower, sections (91a,99a). Herein, the term “upper” in this context referring to the orientation ofFIG. 3.

Thus, preferably theblades90,97 havefront edges91,99 shaped for preferred biasing engagement with thefilter cartridge30.

Preferably opposite edges of the blades, in thisinstance92,98, which are directed toward the inlet end of theair cleaner10, are straight and non-contoured. However alternate configurations for these edges can be used.

Of course a reverse orientation could be used, if it was decided that the seal of the filter cartridge should be against the upstream end, instead of the downstream end, of the housing.

It is noted that is some embodiments it may be desirable to put a second seal on thecartridge40 at an opposite end from theseal arrangement45, analogously to what was done in some of the arrangements of U.S. Provisionals 60/446,804 and 60/457,255 referenced above.

Operation of the biasing andlock mechanism65 can be understood by reference toFIG. 3. Assume, referring toFIG. 3, that theaccess cover11 has been removed from a remainder of thehousing10, and thecartridge30 is positioned in thehousing10 in the general orientation shown (exploded) inFIG. 3.Pin68a is closer to edge16 of thehousing10, than ispin69a. A similar orientation will be found with respect to pin68 and69, along anopposite side70 for thecartridge30, from theside71 which is viewable.

After thecartridge30 is positioned in place, theaccess cover11 would be applied to the remainder of thehousing10, withblade projection85,86, extending downwardly into an interior of thehousing10. The contoured edges of theblades90,97, respectively, would be directed toward theprojection arrangement67. As the contourededge99 is passed (slid) along first thepin68a and then along thepin69a (and the corresponding pins68,67 on the opposite side of thecartridge30 are encountered by edge91), thecartridge30 will be biased axially in the general direction ofarrow61, and into sealing engagement against a portion of thehousing10. The oppositestraight edges98,92,FIG. 5, can be positioned to engage structure within thehousing10, to help presscartridge30 in the direction ofarrow61, and maintain thecartridge30 in the sealing position, as a result. Hence, thestructures85,86 on theaccess cover11 act as a biasing andlock arrangement65 for thecartridge30.

With respect to this, attention is directed toFIG. 6 in which thehousing10 is viewable from an orientation toward theoutlet end16, with thecartridge30 not in position. Along the interior27 of the housing, theprojection85 can be viewed, with contourededge91 directed toward theair outlet16 and with thestraight edge92 oppositely directed. Note that thestraight edge92 is positioned to engageprojection arrangement110 on the housing, in this instance theprojection arrangement110 comprising stays, projections or pins111 and112. Thepins111 and112 can be provided with rollers, if desired, for convenience with respect to wear. Otherwise thepins111,112 may be fixed pins. An analogous structure would be present for theopposite blade86,FIG. 5.

Thecartridge30 can be provided with a handle, not shown, thereon, for convenient handling if desired. It is anticipated that typically thecartridge30 will be positioned within thehousing interior27 before theaccess panel11 is attached. However, theaccess panel11 andcartridge10 can be positioned simultaneously, if desired.

It is noted that theprojections68 and69 can be provided and secured in a variety of matters, including by adhesive attachment, welding or by mechanical connection or other means as appropriate for the particular materials selected. Also, they can be molded or be cast integrally with, and as a portion of, thesheath40. When separately made, theprojections68,69 can be constructed from a moldable material such as a hard plastic, or they can be manufactured from metal.

The particular configurations of theprojections68,69 shown inFIGS. 3 and 4 are examples and are not required. The shape shown is convenient; however a variety of alternate shapes are usable.

InFIG. 3, underneath top22 oraccess panel11, thehousing10 includes aseal groove82 therein, to provide for sealing, with an o-ring, between the top22 and a remainder of thehousing10. Typically, the top22 oraccess panel11 will be mounted by bolts or similar constructions, and receivers for those bolts are shown at84.

Thehousing outlet end26,FIG. 6, can be provided with groove (not shown) therein for receiving a seal member, such as an o-ring or gasket seal, to seal with other constructions or duct work in the system. InFIG. 3, thehousing inlet end25 is shown withgroove120 therein for receiving a seal member, such as an o-ring or gasket seal, for sealing with upstream constructions or duct work.

A variety of different seal types can be utilized for the engagement between theseal member46 on acartridge30, and the seal surface atend26 of thehousing10. The particular arrangement shown forFIGS. 2-6, is an axial seal. In general an axial seal is a seal which operates by seal pressure applied in the axial direction of the filter cartridge, i.e., a direction of a line drawn through themedia31,FIG. 4, in a direction generally parallel with theside wall arrangement40, as shown atarrow50.

Alternates, discussed below in connection withFIGS. 10 and 11, are possible. The type of seal discussed in connection withFIGS. 10 and 11, is a radial seal.

The axial seal may be made from a compressible foam material, for example Durometer Shore A 12-30, that will reduce in thickness when compressed axially. It may alternatively be made from a harder rubber-like material, such as a solid rubber o-ring. Typically it would be preferred that the seal member be compressible and that it compress at least 0.3 mm in thickness, and typically more, when used. This will allow for a convenient sealing.

Referring toFIG. 4, theparticular filter cartridge30 has a generally rectangular or square cross-section, with four curved corners and two pairs of straight sides, although alternates can be used.

Attention is now directed toFIG. 7. InFIG. 7 a fragmentary, schematic, view of z-filter media is shown. Themedia200 includes afluted sheet201 secured to anon-fluted sheet202. Thenon-fluted sheet202, may be corrugated, but it is not shown that way. The upstream end or edge is indicated at203 and the downstream end or edge at204.Flutes205, above thecorrugated sheet201, are open at theupstream end203, for passage of air to be filtered therein. These flutes are closed at thedownstream end204, bysealant210. Outlet flutes are indicated underneath thecorrugated sheet201 at211, closed at the upstream end bysealant215.

Media shown inFIG. 7, can be cut in strips and stacked, to create a stacked arrangement350 such as shown inFIG. 8. Alternatively, the media can be coiled into a coiled shape300 (as shown schematically inFIG. 9).

Those ends of the flutes which are closed, are shown inFIG. 7 as closed by sealant beads. Alternates are possible, for example the ends can be folded, crushed or otherwise distorted, for closure.

A variety of alternate z-filter media configurations to that shown inFIG. 7 can be used. For example tapered flutes in accord with the disclosure of PCT Publication WO 97/40918, can be utilized. Alternatively, flutes which are folded closed at one or more ends in accord with the disclosures of U.S. Provisional 60/395,009 and the PCT Application filed Jan. 31, 2003 and incorporated herein, above, by reference, can be used.

The media may comprise a variety of materials. The particular media choice would depend upon the particular application of use involved. Typically non-woven fibrous constructions, comprising cellulose fibers, synthetic fibers or mixtures of the two, would be used. In some instances a surface application, such as a fine fiber application, can be used for preferred efficiency.

II. An Alternate (Radial) Seal ApproachFIGS.10 and11

Alternately to the axial seal approach described above in connection withFIGS. 2-6, a radial seal approach can be used as demonstrated inFIGS. 10 and 11. Referring toFIG. 10, aseal member400 is shown positioned onstructure401. Thestructure401, for example, can be positioned as part of thefilter cartridge30, for example as part of theside wall40. Theseal member400 includes a sealingsurface405 in this instance having sections orsteps406,407,408. Inregion410, theseal material400 will compress in thickness, radially, as theseal member400 is pushed into an annular portion of a related housing, for use. Arrangements which operate in this manner are sometimes referred to as “radial seals,” since the compression direction of the seal is radial with respect to a central axis50 (FIG. 4) of the filter cartridge.

The particular radial seal depicted inFIG. 10, is an outside radial seal, since it will be directed outwardly fromcentral axis50,FIG. 4. An inside radial seal, or oppositely directed radial seal, can also be used.

InFIG. 11,flange500 securable to a housing, to allow for a radial seal, is shown. Theflange500 includesattachment portion501 and seal member surface withopposite sides505 and506.Surface505 is positioned for receiving an inside radial seal.Surface506 is positioned for receiving an outside radial seal.Structure500 can be mounted at the outlet end ofhousing10, for example, if thefilter cartridge30 includes a radial seal arrangement analogous toarrangement400. Alternatively, the annular surface of the housing, for sealing, can be provided integral with a remainder of the housing.

Radial seal arrangements are described in detail, for example, in the two provisional applications 60/446,804 and 60/457,255, identified above and incorporated herein by reference. The techniques for radial sealing described therein, can be used for the arrangements described herein.

III. Concluding Observations

From the above detailed descriptions, a general understanding of certain preferred principles presented herein is understood. It is noted that the principles can be used together, to form a preferred air cleaner. However selected ones of the principles can be used in various alternate arrangements, if desired.

Among the principles disclosed, is a biasing and lock arrangement which utilizes two depending blades, at opposite sides of a filter cartridge, with an edge of each blade being contoured, instead of simply straight; preferably in the shape shown. The contouring can be used to provide an advantageous biasing to a cartridge member, during positioning of the blades. Preferably a rear end of the blades is straight, and is positioned to engage projections permanently mounted in the housing, for convenience.

A preferred arrangement of contouring is shown, which utilizes two straight sections separated by a third section. The two straight sections are preferably axially spaced, with respect to one another, within the air cleaner. Also, the two straight sections are preferably such as to define lines parallel to one another.

A preferred filter cartridge arrangement is also described. The filter cartridge arrangement generally includes a z-filter media pack surrounded by a sidewall construction. Preferably the sidewall construction has a generally rectangular or square shape, with rounded corners, although alternatives are possible.

Projection arrangements are provided on opposite sides of the sidewall. The projection arrangements preferably comprise posts. Most preferably on each side, at least two posts are spaced axially and vertically from one another, for engagement with sections of biasing and lock blades. This type of positioning can be used to not only help bias the cartridge into position for sealing and to retain it there, but also to ensure that the cartridge is properly positioned within the housing but not improperly installed.

A variety of seal arrangements for the cartridge to the housing are possible. One approach described is using an axial seal contained on the cartridge pressed against a portion of a housing sidewall, axially, in use. Alternatively radial seal approaches can be used.

In general methods of assembly and use are described. Methods of use would involve the steps of inserting the cartridges described, and then applying the biasing lock blade during closure of the air cleaner. Methods of assembly would generally involve assembling the various components, for example in the specific configurations described.

Claims (37)

What is claimed is:

1. An air filter cartridge arrangement comprising:

(a) a media pack having an inlet end and an opposite outlet end;

(i) the media pack including fluted media oriented with flutes extending in a direction between the inlet end and the outlet end; and,

(b) a sidewall arrangement having first and second sides with the media pack positioned therebetween;

(i) the sidewall arrangement including a pair of first and second, axially and vertically spaced, projections on the first side;

(A) axial spacing between the first and second projections comprising spacing in a direction corresponding to a direction between the inlet end and the opposite outlet end; and,

(B) vertical spacing between the first and second projection comprising spacing in a direction corresponding to a direction perpendicular to the direction between the inlet end and the opposite outlet end; and,

(ii) the sidewall arrangement including a pair of third and fourth, axially and vertically spaced, projections on the second side;

(A) axial spacing between the third and fourth projections comprising spacing in a direction corresponding to a direction between the inlet end and the opposite outlet end; and,

(B) vertical spacing between the third and fourth projections comprising spacing in a direction corresponding to a direction perpendicular to the direction between the inlet end and the opposite outlet end.

2. An air filter cartridge according toclaim 1 wherein:

(a) the first, second, third and fourth projections each have a circular cross-section.

3. An air filter cartridge according toclaim 1 wherein:

(a) the media pack comprises a plurality of inlet flutes open adjacent the inlet end and closed adjacent the outlet end; and,

(b) the media pack comprises a plurality of outlet flutes closed adjacent the inlet end and open adjacent the outlet end.

4. An air filter cartridge according toclaim 1 wherein:

(a) the media pack comprises fluted media secured to a facing media.

5. An air filter cartridge according toclaim 4 wherein:

(a) the media pack comprises a continuous strip of fluted media secured to facing media and coiled.

6. An air filter cartridge according toclaim 5 wherein:

(a) the media pack has a rectangular configuration with: a first pair of opposite, generally parallel, sides; and, a second pair of opposite, generally parallel, sides; and, four rounded corners.

7. An air filter cartridge according toclaim 6 wherein:

(a) the sidewall arrangement surrounds the media pack.

8. An air filter cartridge according toclaim 7 wherein:

(a) the sidewall arrangement is an impermeable sheath.

9. An air filter cartridge according toclaim 1 including:

(a) a first, primary, seal arrangement.

10. An air filter cartridge according toclaim 9 wherein:

(a) the first, primary, seal arrangement comprises an axial seal.

11. An air filter cartridge according toclaim 9 wherein:

(a) the first, primary, seal arrangement comprises a radial seal.

12. An air filter cartridge according toclaim 11 wherein:

(a) the first, primary, seal arrangement is an inside radial seal.

13. An air filter cartridge according toclaim 11 wherein:

(a) the first, primary, seal arrangement is an outside radial seal.

14. An air filter cartridge according toclaim 1 wherein:

(a) the media pack comprises a stack of strips of fluted media secured to facing media.

15. An air cleaner arrangement including:

(a) a housing having: a sidewall; an inlet end; and an outlet end;

(i) the housing sidewall including an access cover removable from a remainder of the housing; and,

(b) an air filter cartridge comprising:

(i) a media pack having an inlet end and an opposite outlet end;

(A) the media pack including fluted media oriented with flutes extending in a direction between the inlet and outlet ends of the media pack; and,

(ii) a sidewall arrangement having first and second sides with the media pack positioned therebetween;

(A) a sidewall arrangement including a pair of first and second, axially and vertically spaced, projections on the first side;

(1) axial spacing between the first and second projections comprising spacing in a direction corresponding to a direction between the inlet end and opposite outlet end of the media pack; and,

(2) vertical spacing between the first and second projections comprising spacing in a direction corresponding to a direction perpendicular to the direction between the inlet end and the opposite outlet end of the media pack; and,

(B) the sidewall arrangement including a pair of third and fourth, axially and vertically spaced, projections on the second side;

(1) axial spacing between the third and fourth projections comprising spacing in a direction corresponding to a direction between the inlet end and opposite outlet end of the media pack; and,

(2) vertical spacing between the third and fourth projections comprising spacing in a direction corresponding to a direction perpendicular to the direction between the inlet end and the opposite outlet end of the media pack; and,

(c) first and second biasing and lock blades secured to the access cover and projecting along opposite sides of the air filter cartridge;

(i) the air filter cartridge being removably positioned in the housing;

(ii) the first biasing and lock blade having a non-straight, contoured, forward edge in engagement with the first and second projections; and,

(iii) the second biasing and lock blade having a non-straight, contoured, forward edge in engagement with the third and fourth projections; and,

(iv) the forward edges of the biasing and lock blades engaging the filter cartridge to secure the filter cartridge in a sealing orientation.

16. An air cleaner arrangement according toclaim 15 wherein:

(a) the first biasing and lock blade has a straight, rear, edge opposite the contoured front edge; and

(b) the second biasing and lock blade has a straight, rear, edge opposite the contoured front edge;

(c) the straight rear edges of the first and second biasing and lock arrangement being in contact with posts positioned on the housing sidewall and inside the housing.

17. An engine intake system comprising:

(a) an engine

(b) a turbocharger; and,

(c) an air cleaner arrangement positioned downstream from the turbocharger; the air cleaner arrangement comprising;

(i) a housing having: a sidewall; an inlet end and an outlet end;

(A) the housing sidewall including an access cover removable from a remainder of the housing; and,

(ii) an air filter cartridge comprising:

(A) a media pack having an inlet end and an opposite outlet end;

(1) the media pack including fluted media oriented with flutes extending in a direction between the inlet and outlet ends of the media pack; and,

(B) a sidewall arrangement having first and second sides with the media pack positioned therebetween;

(1) the sidewall arrangement including a pair of first and second, axially and vertically spaced, projections an the first side;

 axial spacing between the first and second projections comprising spacing in a direction corresponding to a direction between the inlet end and opposite outlet end of the media pack; and, vertical spacing between the first and second projections comprising spacing in a direction corresponding to a direction perpendicular to the direction between the inlet end and the opposite outlet end of the media pack; and,

(2) the sidewall arrangement including a pair of third and fourth, axially and vertically spaced, projections an the second side;

 axial spacing between the third and fourth projections comprising spacing in a direction corresponding to a direction between the inlet end and opposite outlet end of the media pack; and, vertical spacing between the third and fourth projections comprising spacing in a direction corresponding to a direction perpendicular to the direction between the inlet end and the opposite outlet end of the media pack.

18. An air filter cartridge arrangement comprising:

(a) a media pack having an inlet end and an opposite outlet end;

(b) a sidewall arrangement having first and second sides with the media pack positioned therebetween;

(i) the sidewall arrangement including a first projection arrangement extending from the first side in a direction away from the first side, the first projection arrangement comprising first and second, axially and vertically spaced, contact locations;

(A) axial spacing between the first and second contact locations comprising spacing in a direction corresponding to a direction between the inlet end and the opposite outlet end; and

(B) vertical spacing between the first and second contact locations comprising spacing in a direction corresponding to a direction perpendicular to the direction between the inlet end and the opposite outlet end; and

(ii) the sidewall arrangement including a second projection arrangement extending from the second side in a direction away from the second side, the second projection arrangement comprising third and fourth, axially and vertically spaced, contact locations;

(A) axial spacing between the third and fourth contact locations comprising spacing in a direction corresponding to a direction between the inlet end and the opposite outlet end; and

(B) vertical spacing between the third and fourth contact locations comprising spacing in a direction corresponding to a direction perpendicular to the direction between the inlet end and the opposite outlet end; and

(c) a primary seal arrangement.

19. An air filter cartridge according to claim 18 wherein:

(a) the media pack has a non-circular cross-section.

20. An air filter cartridge according to claim 18 wherein:

(a) the sidewall arrangement surrounds the media pack.

21. An air filter cartridge according to claim 20 wherein:

(a) the sidewall construction is an impermeable sheath.

22. An air filter cartridge according to claim 18 wherein:

(a) the primary seal arrangement comprises an axial seal.

23. An air filter cartridge according to claim 18 wherein:

(a) the primary seal arrangement comprises a radial seal.

24. An air filter cartridge according to claim 23 wherein:

(a) the primary seal arrangement is an inside radial seal.

25. An air filter cartridge according to claim 23 wherein:

(a) the primary seal arrangement is an outside radial seal.

26. An air cleaner arrangement according to claim 18 wherein:

(a) the first and second contact locations each comprise a surface perpendicular to a central longitudinal axis extending through the media pack from the inlet end to the outlet end; and

(b) the third and fourth contact locations each comprise a surface perpendicular to a central longitudinal axis extending through the media pack from the inlet end to the outlet end.

27. An air cleaner arrangement according to claim 18 wherein:

(a) the vertical spacing between the first and second contact locations comprises at least 20% of the length of first side of the sidewall arrangement; and

(b) the vertical spacing between the third and fourth contact locations comprises at least 20% of the length of second side of the sidewall arrangement.

28. An air cleaner arrangement including:

(a) a housing having: a sidewall; an inlet end; and an outlet end;

(i) the housing sidewall including an access cover removable from a remainder of the housing;

(b) an air filter cartridge installed in a sealing orientation within the housing and comprising:

(i) a media pack having an inlet end and an opposite outlet end;

(ii) a first sidewall and an opposite second sidewall with the media pack positioned therebetween;

(A) the first sidewall comprises a first projection arrangement and the second sidewall comprises a second projection arrangement;

(c) first and second biasing and lock blades secured to the access cover and projecting along the first sidewall and the second sidewall of the air filter cartridge;

(i) the air filter cartridge being removably positioned in the housing;

(ii) the first biasing and lock blade having a non-straight, contoured, filter cartridge engagement edge is constructed to engage the first projection arrangement of the first sidewall so that the air filter cartridge is provided in the sealing orientation within the housing when the access cover is installed on the housing;

(iii) the second biasing and lock blade having a non-straight, contoured, filter cartridge engagement edge, wherein the non-straight, contoured, filter cartridge engagement edge is constructed to engage the second projection arrangement of the second sidewall so that the air filter cartridge is provided in the sealing orientation within the housing when the access cover is installed on the housing;

(d) the projection arrangement on the first sidewall comprises a first contact location and a second contact location for engaging the first biasing and lock blade, wherein one of the first contact location or the second contact location is located closer to the housing outlet than the other of the first contact location or the second contact location when the air filter cartridge is installed in the sealing orientation; and

(e) the projection arrangement on the second sidewall comprises a third contact location and a fourth contact location for engaging the second biasing and lock blade, wherein one of the third contact location or the fourth contact location is located closer to the housing outlet than the other of the third contact location or the fourth contact location when the air filter cartridge is installed in the sealing orientation.

29. An air cleaner arrangement according to claim 28 wherein:

(a) the non-straight, contoured filter engagement edge of the first biasing and lock blade is a front edge; and

(b) the non-straight, contoured filter engagement edge of the second biasing and lock blade is a front edge.

30. An air cleaner arrangement according to claim 28 wherein:

(a) the non-straight, contoured, filter cartridge edge of the first biasing and lock blade is constructed to engage the projection arrangement at the first contact location and at the second contact location offset by a distance of at least 20% of the length of the first sidewall; and

(b) the non-straight, contoured, filter cartridge edge of the second biasing and lock blade is constructed to engage the projection arrangement at the third contact location and at the fourth contact location offset by a distance of at least 20% of the length of the second sidewall.

31. An air cleaner arrangement according to claim 28 wherein:

(a) the media pack has a non-circular cross-section.

32. An air cleaner arrangement according to claim 28 including:

(a) a primary seal arrangement.

33. An air cleaner arrangement according to claim 32 wherein:

(a) the primary seal arrangement comprises an axial seal.

34. An air cleaner arrangement according to claim 32 wherein:

(a) the primary seal arrangement comprises a radial seal.

35. An air cleaner arrangement according to claim 34 wherein:

(a) the primary seal arrangement is an inside radial seal.

36. An air cleaner arrangement according to claim 34 wherein:

(a) the primary seal arrangement is an outside radial seal.

37. An air cleaner arrangement according to claim 28 wherein:

(a) the non-straight, contoured, filter cartridge edge of the first biasing and lock blade engages the projection arrangement of the first sidewall at the first contact location and at the second contact location when the air filter cartridge is provided in the sealing orientation within the housing; and

(b) the non-straight, contoured, filter cartridge edge of the second biasing and lock blade engages the projection arrangement of the second sidewall at the third contact location and at the fourth contact location when the air filter cartridge is provided in the sealing orientation within the housing.

Images