Filter with interlocking housing interface

A filter element includes first filter media, second filter media, a frame, and a seal member. The frame is coupled to the first filter media and the second filter media, the frame securing the first filter media and the second filter media into a V-shape. The seal member is attached to and extends from the frame. The seal member includes a U-shaped channel structured to receive a ridge of a housing when the filter element is installed in the housing. The seal member is structured to form a seal between the filter element and the housing when the filter element is installed in the housing.

TECHNICAL FIELD

The present application relates to filter elements for use with filtration systems.

BACKGROUND

Internal combustion engines generally combust a mixture of fuel (e.g., gasoline, diesel, natural gas, etc.) and air. Prior to entering the engine, intake air is typically passed through a filter element to remove contaminants (e.g., particulates, dust, water, etc.) from the intake air prior to delivery to the engine. The filter element requires periodic replacement as the filter media of the filter element captures and removes particulate from the intake air passing through the filter media. Accordingly, the filter element is typically removably received in the housing such that when the filter element is installed, a seal is formed between the filter element and the housing preventing bypass of the intake air around the filter element. The use of a non-authorized filter element in a filtration system may lead to a poor seal or no seal thereby allowing intake air to bypass the filter element, which can damage the internal combustion engine.

SUMMARY

Various example embodiments relate to filter elements. One such filter element includes first filter media and second filter media. The filter element further includes a frame member coupled to the first filter media and the second filter media. The frame member secures the first filter media and the second filter media (such as into a V-shape). The filter element includes a seal member is attached to and extends from the frame member. The seal member includes a U-shaped channel structured to receive a ridge of a housing when the filter element is installed in the housing. The seal member is structured to form a seal between the filter element and the housing when the filter element is installed in the housing.

In an embodiment, a filter element includes first filter media, second filter media, a frame, and a seal member. The frame is coupled to the first filter media and the second filter media, the frame securing the first filter media and the second filter media. The seal member is attached to and extends from the frame. The seal member includes a U-shaped channel structured to receive a ridge of a housing when the filter element is installed in the housing. The seal member is structured to form a seal between the filter element and the housing when the filter element is installed in the housing.

In another embodiment, a filtration system includes a housing and a filter element. The housing includes a keyway. The filter element is positioned within the housing. The filter element includes first filter media, second filter media, and a frame. The frame is coupled to the first filter media and the second filter media. The frame secures the first filter media and the second filter media. The keyway interfaces with the filter element to facilitate positioning of the filter element within the housing.

In still another embodiment, a filter element includes first filter media, second filter media, and a frame. The frame is coupled to the first filter media and the second filter media. The frame secures the first filter media and the second filter media. The frame includes a first frame member, a second frame member, a first side wall, and a second side wall. The first frame member is coupled to a first end of the first filter media and a first end of the second filter media. The second frame member is coupled to a second end of the first filter media, opposite the first end of the first filter media, and a second end of the second filter media, opposite the first end of the second filter media. The first side wall is positioned along a first side of the first filter media and a first side of the second filter media. The first side wall is coupled to the first frame member and the second frame member. The second side wall is positioned along a second side of the first filter media, opposite the first side of the first filter media, and a second side of the second filter media, opposite the first side of the second filter media.

DETAILED DESCRIPTION

Referring to the figures generally, a filtration system having a filter element removably received in a housing is shown. In some arrangements, the filter element includes two panel filters coupled to a frame that secure the panel filters in a V-shape such that a cross-section of the filter element has a V-shape. In other arrangements, the filter element includes filter media arranged in an alternate shape, such as a rectangular panel, a cylindrical shape, or the like. The filter media comprising the filter element may be pleated or non-pleated. The filter element includes a seal having an alignment channel. The housing includes an alignment rib that is received in the alignment channel of the filter element when the filter element is installed in the housing. A cover is removably secured to the housing. When the cover is secured to the housing and the filter element is installed in the housing, the cover compresses the seal member against the housing forming an axial seal between the housing and the filter element. In some arrangements, the seal member does not form a radial seal against the housing. In other arrangements, the seal member forms only a radial seal or a combination of a radial and axial seal.

Referring toFIG. 1, a perspective view of a filtration system100is shown according to an example embodiment. Referring toFIG. 2andFIG. 3, cross-sectional views of the filtration system100are shown. Referring toFIG. 4, an exploded view of the filtration system100is shown. The filtration system100includes a housing102and a cover104. The cover104is removably coupled to the housing102. The cover104may be removably coupled to the housing102through fasteners (e.g., screws), clamps, snap fit connections, or a combination thereof. The cover includes an air inlet106structured to provide air to be filtered to the filtration system100. The housing102includes an air outlet108structured to provide filtered air to a component, such as an internal combustion engine. As shown best inFIGS. 2 through 4, a filter element110is removably received within the housing102and the cover104. The filter element110has a V-shaped cross section (as shown inFIG. 2).

Referring toFIGS. 5-12, various views of the filter element110of the filtration system100are shown. The filter element110includes first filter media112and second filter media114. In some arrangements, the first filter media112and the second filter media114are panel filters that form the filter element110. The first filter media112and the second filter media114may be the same type of filter media or different filter media. In some arrangements, the first filter media112and the second filter media114are pleated filter blocks as described in U.S. Pat. No. 6,375,700, entitled “DIRECT FLOW FILTER,” which is herein incorporated by reference in its entirety and for all purposes. In some arrangements, the pleat tips of the first and second filter media112and114are blocked on one end and open on the other end. In other arrangements, the pleat tips are blocked on both ends.

The filter element110includes a frame comprising a first frame member116and a second frame member118. The first frame member116and the second frame member118secure the first filter media112and the second filter media114into a V-shape (e.g., as shown inFIG. 2). The first frame member116and the second frame member118provide durability and structure to the filter element110and serve as manufacturing fixtures during manufacturing of the filter element110. The first frame member116and the second frame member118protect the first and second filter media112and114during manufacturing and during installation of the filter element110into the housing102. As shown best inFIG. 12, the second frame member118wraps around the edge of the first and second filter media112and114limiting the exposure of the first and second filter media112and114to come in contact with other objects (e.g., the housing102during installation of the filter element110). The rigidity created by the first and second frames116and118also improve the aesthetics and durability of the filter element110. The rigidity helps to prevent the first filter media112and the second filter media114from collapsing during use and limits the stress on the first filter media112and the second filter media114during sealing (as described below with respect to the seal member124). Further the first and second frames116and118provide a grip area for a technician installing the filter element110into the housing102or removing an installed filter element110from the housing102.

The first filter media112and the second filter media114may include any of pleated media, corrugated media, tetrahedral media, or variations thereof. U.S. Pat. No. 8,397,920, entitled “PLEATED FILTER ELEMENT WITH TAPERING BEND LINES,” by Moy et al., filed on Oct. 14, 2011, and issued on Mar. 19, 2013, assigned to Cummins Filtration IP Inc., which is incorporated by reference in its entirety and for all purposes, describes a tetrahedral filter media. Some configurations of tetrahedral filter media include a plurality of inlet tetrahedron flow channels and a plurality of outlet tetrahedron flow channels. The inlet tetrahedron merge in a central portion of the filter material, thereby allowing axial cross-flow of air between the inlet tetrahedron channels prior to the air passing through the filter media. Such an arrangement provides for additional dust loading on the upstream side of the media, which increases filter capacity. The tetrahedral flow channels may be stacked, layered, or coiled into various shapes and configurations. For example, the first and second filter media112and114may have, for example, thirty to eighty stacked layers of tetrahedral flow channels. These stacked layers of tetrahedral flow channels can be arranged to form various shapes. For example, layers of tetrahedral flow channels, the layers having different lengths and/or widths, can be stacked such that the stacked layers of tetrahedral flow channels substantially match the V-shape of the filter element110as shown and described. Specific arrangements of such tetrahedral filter media are further described in U.S. Pat. No. 8,397,920.

The filter element110includes side walls120. In some arrangements, the side walls120are comprised of urethane. Alternatively, the side walls120be comprised of plastisol. In such arrangements, the first filter media112and the second filter media114may be potted into or overmolded into the side walls120. For example, a face of a first pleat within the first filter media112and a face of a first plate within the second filter media114may be potted into one of the side walls120, and a face of a second pleat within the first filter media112and a face of a second plate within the second filter media114may be potted into the other of the side walls120.

In some arrangements, the side walls120each have a trapezoidal shape. In some arrangements, the side walls120include a flat surface for receiving a label (e.g., a product label or identifier). The outer perimeter thickness of the side walls120is controlled during manufacturing by using a closed mold, which allows for a controlled surface with which to engage during additional manufacturing operations. Additionally, the first and second frames116and118include urethane shut-off ridges122that prevent the urethane forming the side walls120from over-expanding and blow (as shown inFIGS. 6, 7, and 10). The tapered shape of the filter element110allows for improved filter alignment and serviceability.

The filter element110includes a seal member124. As shown inFIG. 3, when the filter element110is installed in the housing102, the seal member124is compressed by the cover104against the housing102and forms an axial seal with the housing102. In some arrangements, the seal member124is urethane. In such arrangements, the seal member124may be overmolded over the first frame member116and the side walls120. The axial seal prevents air entering the filtration system100through the inlet106from bypassing the filter element110. As shown inFIGS. 5, 7, and 8, the seal member124includes a U-shaped channel126. The U-shaped channel126receives a ridge of the housing102(as shown inFIG. 3). The interaction between the U-shaped channel126and the ridge helps to align the filter element110during installation of the filter element110into the housing102. During installation, when the cover104is secured to the housing102, a ridge128on the cover104presses into the seal member124to help form the axial seal.

In some arrangements, the seal member124does not include a U-shaped channel. According to some embodiments, the seal member124has a stepped geometry. In these embodiments, the seal member124may provide multiple sealing faces that interface with the cover104. The top and/or bottom of the seal member124may be stepped in this fashion such that the seal member124may be tailored for a target application.

Referring again toFIG. 4, the housing102includes a keyway130that receives and guides the filter element110during installation of the filter element into the housing102. The keyway allows the filter element110and the housing102to nest together. The keyway130is structured to function as a support surface that generally limits the amount of movement of the filter element110within the housing, thereby limiting the strain on the filter element110caused by vibration or heavy loading on the filter element110during operation of the filtration system100. The keyway130also prevents the filter element110from sagging during horizontal configurations of the filter element. In some arrangements, the keyway130is angled to match the angle of the V-shape of the filter element110. In further arrangements, the keyway130includes an internal rib that provides a positive stop to limit movement of the filter element110during installation. In some arrangements, the housing also includes a side-support keyway132that supports the side of the filter element110within the housing102(e.g., as shown inFIG. 4). In such arrangements, the side-support keyway132is angled to match the V-shaped contour of the side walls120of the filter element110. The interaction of the filter element110with the keyway130and the side-support keyway132are shown inFIGS. 13 and 14.

During operation of the filtration system100, air to be filtered enters in through the inlet106and passes into the central area of the V-shape formed between the first filter media112and the second filter media114through the supports of the first frame member116. The air then passes through the first filter media112and the second filter media114, where the first filter media112and the second filter media114removes and captures contaminants in the air (e.g., dust, dirt, moisture, etc.). The filtered air then exits the housing102through the outlet108. Accordingly, the air flows in a general air flow direction designated by arrow134ofFIG. 1. When the filter element110is replaced, the V-shaped pocket formed between the first filter media112, the second filter media114, and the two side walls120contains all of the captured contaminants thereby resulting in a clean filter cartridge service. In an alternative arrangement, the filtration system100is structured to have airflow move in the opposite direction. Such an arrangement is shown inFIGS. 15 and 16. In such an arrangement, the cover104may be fitted with an outlet hood136. In either arrangement, the cover104can be formed to receive and/or distribute the air directly from the open area between the first filter media112and the second filter media114thereby improving the flow characteristics of the system.

FIGS. 17 through 25show additional views of the filtration system100and its components. As shown specifically inFIG. 17, the second frame member118may receive a single urethane seal. In this way, a de-molding operation may not be required when assembling filter element110. The single urethane seal may contact both the first filter media112and the second filter media114.

It should be noted that any use of the term “example” herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

It is important to note that the construction and arrangement of the various example embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Additionally, features from particular embodiments may be combined with features from other embodiments as would be understood by one of ordinary skill in the art. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various example embodiments without departing from the scope of the present invention.