Direct flow filter

A filter (10, 10a) includes a housing (12, 12a) extending along an axis (14). and having an inlet (16, 16a) at one axial end (18, 18a) of the housing and having an outlet (20, 20a) at a distally opposite axial end (22, 22a) of the housing. One or more pleated filter elements (44, 44a, 44b, 44c, 44d) in the housing are pleated along a plurality of bend lines (46, 48) extending axially. The filter element has a plurality of wall segments (50) extending in serpentine manner between the bend lines. The wall segments extend axially between upstream ends (52) and downstream ends (54) and define axial flow channels (58, 62) therebetween. The upstream ends of the wall segments are alternately sealed (56) to each other to defme a first set of flow channels (58) having open upstream ends (60), and a second set of flow channels (62) interdigitated with the first set of flow channels and having closed upstream ends (64). The downstream ends of the wall segments are alternately sealed to each other (66) such that the first set of flow channels have closed downstream ends (68), and the second set of flow channels have open downstream ends (70). Fluid to be filtered flows substantially directly axially through the filter element (44) or elements (44a, 44b, 44c, 44d), through the open upstream ends of the first set of flow channels then through the wall segments then through the open downstream ends of the second set of flow channels. A gasket (82, 82a, 82b, 82c) seals the filter element to the housing.

BACKGROUND AND SUMMARY

The invention relates to fluid filters, including panel type air cleaners.

It is known in the prior art to use pleated filter blocks for various fluid filtering applications, including panel type air cleaners. The present invention arose during development efforts directed toward improving space efficiency, capacity, and performance, i.e. reduced pressure drop, of classical panel air filters.

The present invention provides a direct substantially straight-through flow filter. The elimination of directional changes in flow reduces flow resistance and pressure drop, improving filtration performance and enabling higher flow rates. The invention also enables more efficient space utilization, i.e. eliminating large open areas within the filter housing between the filter element and the housing, which is particularly desirable in space constrained areas such as behind the cabin or under the hood of vehicles.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a filter 10 including a housing 12 extending axially along axis 14 and having an inlet 16 at one axial end 18 of the housing and having an outlet 20 at a distally opposite axial end 22 of the housing. The housing is preferably plastic and provided by identical upper and lower half sections 24 and 26 mating along diagonal flanges 28 , 30 , lateral flanges 32 , 34 , diagonal flanges 36 , 38 , and lateral flanges 40 , 42 .

A pleated filter block is provided by pleated filter element 44 in the housing. The pleated filter element is pleated along a plurality of upper bend lines 46 and lower bend lines 48 , which bend lines extend axially. The filter element has a plurality of wall segments 50 extending in serpentine manner between the upper and lower bend lines. The wall segments extend axially between upstream ends 52 at inlet 16 , and downstream ends 54 at outlet 20 . The wall segments defme axial flow channels 55 therebetween, FIG. 2 . The upstream ends of the wall segments are alternately sealed to each other, as shown at 56 in FIG. 2 , to define a first set of flow channels 58 having open upstream ends 60 , and a second set of flow channels 62 interdigitated with the first set of flow channels 58 and having closed upstream ends 64 . The downstream ends 54 of wall segments 50 are alternately sealed to each other, as shown at 66 in FIG. 2 , such that the first set of flow channels 58 have closed downstream ends 68 , and the second set of flow channels 62 have open downstream ends 70 . Fluid to be filtered, such as air, flows substantially directly axially through filter element 44 , namely from inlet 16 through open upstream ends 60 of the first set of flow channels 58 as shown at arrows 72 , then through wall segments 50 as shown at arrows 74 , then through open downstream ends 70 of the second set of flow channels 62 as shown at arrows 76 , then to outlet 20 . It is preferred that at least a portion of each of inlet 16 and outlet 20 are axially aligned.

Filter element 44 has laterally distally opposite right and left axially extending sides 78 and 80 , FIG. 1 , defining first and second axially extending planes. The second axial plane at side 80 is parallel to and spaced from the first axial plane at side 78 . Upper bend lines 46 provide a first or upper set of coplanar bend lines defining a third axially extending plane. Lower bend lines 48 define a lower or second set of coplanar bend lines defining a fourth axially extending plane. The fourth axial plane at lower bend lines 48 is parallel to and spaced from the third axial plane at upper bend lines 46 . The third and fourth axial planes are perpendicular to the noted first and second axial planes. Upstream ends 52 of wall segments 50 define a first laterally extending plane, and downstream ends 54 of the wall segments define a second laterally extending plane. The second lateral plane at downstream ends 54 is parallel to and spaced from the first lateral plan e at upstream ends 52 . The noted first and second lateral planes are perpendicular to the noted first and second axial planes and perpendicular to the noted third and fourth axial planes.

A gasket 82 , FIGS. 1 , 3 , is provided for sealing filter 44 to housing 12 , such that air entering inlet 16 cannot bypass the filter element to outlet 20 , and instead must flow through the filter element as shown at arrows 72 , 74 , 76 , FIG. 2 . Gasket 82 has a first section 84 extending along the noted first axial plane along right side 78 . Gasket 82 has a second section 86 extending along the noted second lateral plane at downstream ends 54 as shown at 88 in FIG. 3 , and also extending along the noted third axial plane at upper bend lines 46 , as shown at 90 in FIG. 3 . In alternate embodiments, second section 86 of gasket 82 extends along only one or the other of the noted second lateral plane at 88 or third axial plane at 90 , but not both. Gasket 82 has a third section 92 extending along the noted second axial plane along left side 80 . Gasket 82 has a fourth section 94 extending along the noted first lateral plane at upstream ends 52 of wall segments 50 , and also extending along the noted fourth axial plane at lower bend lines 48 , comparably to FIG. 3 . In alternate embodiments, fourth section 94 of gasket 82 extends along only one or the other of the noted first lateral plane and fourth axial plane, but not both. Gasket 82 is preferably adhesively secured to filter element 44 along each of the noted gasket sections 84 , 86 , 92 , 94 , such that filter element 44 and gasket 82 are replaced as a modular unit. It is further preferred that the upper and lower surfaces of the gasket, such as 96 and 98 , FIG. 3 , be pinched and compressed between respective housing flanges such as 32 and 34 , with such outer peripheral sandwich arrangement being held in assembled condition by any suitable means, such as clip 100 , clamps, bolts, or the like. In alternate embodiments, other surfaces of the gasket may be used as the sealing surface against the housing. First and third gasket sections 84 and 92 extend obliquely relative to axis 14 . Second and fourth gasket sections 86 and 94 extend perpendicularly to the noted first and second axial planes. Second and fourth gasket sections 86 and 94 are axially spaced, and first and third gasket sections 84 and 92 extend diagonally between second and fourth gasket sections 86 and 94 .

FIG. 4 shows a further embodiment having a plurality of filter elements 44 a , 44 b , 44 c stacked on each other. The filter elements have respective wall segments 50 a , 50 b , 50 c with upstream ends 52 a , 52 b , 52 c and downstream ends 54 a , 54 b , 54 c . Upstream ends 52 a , 52 b , 52 c of the wall segments are coplanar along a first laterally extending plane. Downstream ends 54 a , 54 b , 54 c are coplanar along a second laterally extending plane. The second lateral plane is parallel to and spaced from the first lateral plane. The filter elements have respective laterally distally opposite right and left sides 78 a and 80 a , 78 b and 80 b , 78 c and 80 c . Right sides 78 a , 78 b , 78 c are coplanar along a first axially extending plane. Left sides 80 a , 80 b , 80 c are coplanar along a second axially extending plane. The second axial plane is parallel to and spaced from the first axial plane. The filter elements 44 a , 44 b , 44 c have respective upper sets of coplanar bend lines 46 a , 46 b , 46 c , and lower sets of coplanar bend lines 48 a , 48 b , 48 c . The upper set of coplanar bend lines 46 a of top filter 44 a defines a third axially extending plane. The lower set of coplanar bend lines 48 c of the bottom filter element 44 c defines a fourth axially extending plane. The fourth axial plane is parallel to and spaced from the third axial plane. The third and fourth axial planes are perpendicular to the first and second axial planes. The noted first and second lateral planes are perpendicular to the noted first and second axial planes and perpendicular to the noted third and fourth axial planes. Gasket 82 a has a first section 84 a extending along the noted first axial plane along right sides 78 a , 78 b , 78 c . Gasket 82 a has a second section 86 a extending along the noted second lateral plane along downstream ends 54 a , and also along the noted third axial plane along upper bend lines 46 a . In alternate embodiments, gasket section 86 a extends along only one or the other of the noted second lateral plane along downstream ends 54 a or along the noted third axial plane along upper bend lines 46 a , but not both. Gasket 82 a has a third section 92 a extending along the noted second axial plane along left sides 80 a , 80 b , 80 c . Gasket 82 a has a fourth section 94 a extending along the noted first lateral plane along upstream ends 52 a , 52 b , 52 c , and also extending along the noted fourth axial plane along lower bend lines 48 c . In alternate embodiments, gasket section 94 a extends along only one of the noted first lateral plane along upstream ends 52 a , 52 b , 52 c or the noted fourth axial plane along lower bend lines 48 c , but not both. The construction in FIG. 4 provides a pleated filter block having one or more rows of wall segments 50 a , 50 b , 50 c folded in serpentine manner between respective bend lines, and providing filtered fluid flow substantially directly axially through the filter block along axis 14 . First and third gasket sections 84 a and 92 a extend obliquely relative to axis 14 . Second and fourth gasket sections 86 a and 94 a extend perpendicularly to the noted first and second axial planes. Second and fourth gasket sections 86 a and 94 a are axially spaced, and first and third gasket sections 84 a and 92 a extend diagonally between second and fourth gasket sections 86 a and 94 a.

FIG. 5 shows a further embodiment, and uses like reference numerals from above where appropriate to facilitate understanding. Filter 10 a includes a housing 12 a extending axially along axis 14 and having an inlet 16 a at one axial end 18 a of the housing and having an outlet 20 a at a distally opposite axial end 22 a of the housing. The housing is preferably plastic and provided by a box-like member 102 having an outer peripheral flange 104 mating with flange 106 of housing end 22 a and pinching gasket 82 b therebetween. Gasket 82 b seals pleated filter block 44 or 44 a in the housing. Unlike first and third sections 84 and 92 of gasket 82 in FIG. 1 , first and third sections 84 b and 92 b of gasket 82 b in FIG. 5 extend perpendicularly relative to the noted third and fourth axial planes. Like second and fourth sections 86 and 94 of gasket 82 in FIG. 1 , second and fourth sections 86 b and 94 b of gasket 82 b in FIG. 5 extend perpendicularly to the noted first and second axial planes. Gasket 82 b has first section 84 b extending along the noted first axial plane along right side 78 and also preferably extending along one of the noted lateral planes preferably the noted second lateral plane along downstream ends 54 . Gasket 82 b has second section 86 b extending along the noted third axial plane along upper bend lines 46 and also along the noted one lateral plane preferably the lateral plane along downstream ends 54 . Gasket 82 b has third section 92 b extending along the noted second axial plane along left side 80 and preferably along the noted one lateral plane preferably the lateral plane formed at downstream ends 54 . Gasket 82 b has fourth section 94 b extending along the noted fourth axial plane along the noted lower bend lines 48 and also preferably along the noted one lateral plane preferably the lateral plane along downstream ends 54 .

FIG. 6 shows a further embodiment and uses like reference numerals from above where appropriate to facilitate understanding. Filter elements 44 a , 44 b , 44 c , 44 d are stacked on each other. Gasket 82 c corresponds to gasket 82 b of FIG. 5 and includes corresponding gasket sections 84 c , 86 c , 92 c , 94 c.

FIG. 7 is similar to FIG. 6 and uses like reference numerals from above where appropriate to facilitate understanding. Layers of sealing material 110 , 112 , etc. are between respective adjacent stacked filter elements, FIG. 8 . In one embodiment, each layer 110 , 112 , etc. is impervious to the noted fluid to be filtered. In another embodiment, each layer 110 , 112 , etc. is pervious to such fluid and filters fluid flow therethrough. In the embodiment of FIGS. 7 and 8 , each layer 110 , 112 , etc. spans the entire area between upstream ends 52 and downstream ends 54 and between right and left sides 78 and 80 .

FIGS. 9-15 show another embodiment wherein the noted sealing layers of FIGS. 7 and 8 need not span the entire noted area between upstream and downstream ends 52 and 54 and right and left sides 78 and 80 . In FIGS. 9-15 , the noted sealing layers are provided by alternating strip layers such as 120 , 122 , 124 , 126 , 128 , FIGS. 9 , 10 , including a first set of one or more upstream laterally extending strip layers 122 , 126 , etc., and a second set of one or more downstream laterally extending strip layers 120 , 124 , 128 , etc., interdigitated with the first set of strip layers. Each strip layer 122 , 126 , etc. of the first set extends laterally between the right and left sides 78 and 80 at upstream end 52 and extends along the lower bend lines of the filter element thereabove and the upper bend lines of the filter element therebelow. Each strip layer 120 , 124 , 128 , etc. of the second set extends laterally between right and left sides 78 and 80 at downstream end 54 and extends along the lower bend lines of the filter element thereabove and the upper bend lines of the filter element therebelow. A given filter element, e.g. 44 b , has a strip layer 122 of the first set extending laterally along its upper bend lines at upstream end 52 , and a strip layer 124 of the second set extending laterally along its lower bend lines at downstream end 54 . Filter element 44 b has no strip layer along its upper bend lines at downstream end 54 , and has no strip layer along its lower bend lines at upstream end 52 .

A first filter element such as 44 a has a first strip layer 122 of the first set extending along its lower bend lines at upstream end 52 , a second filter element such as 44 b has a first strip layer 124 of the second set extending laterally along its lower bend lines at downstream end 54 , a third filter element such as 44 c has a second strip layer 126 of the first set extending along its lower bend lines at upstream end 52 . The noted first and second filter elements 44 a and 44 b have the first strip layer 122 of the first set extending laterally therebetween at upstream end 52 . The noted first and second filter elements 44 a and 44 b have no strip layer extending laterally therebetween at downstream end 54 . The noted second and third filter elements 44 b and 44 c have first strip layer 124 of the second set extending laterally therebetween at downstream end 54 . The noted second and third filter elements 44 b and 44 c have no strip layer extending laterally therebetween at upstream end 52 .

As shown in FIGS. 13 and 14 , the closed upstream ends of the noted second set of flow channels are closed by sealing material such as 130 at filter element 44 a , 132 at filter element 44 b , 134 at filter element 44 c , 136 at filter element 44 d . The closed downstream ends of the first set of flow channels are closed by sealing material such as 138 , FIG. 15 , at filter element 44 a , 140 at filter element 44 b , 142 at filter element 44 c , 144 at filter element 44 d . Lateral sealing strip 122 , FIGS. 13 , 14 , is sealed to the sealing material 130 in the closed upstream ends of the flow channels of filter element 44 a thereabove and is sealed to sealing material 132 in the closed upstream ends of the flow channels of filter element 44 b therebelow. Lateral strip 122 may be adhesively bonded to sealing material 130 , 132 , or may be integrally formed therewith as in a hot melt application, or the like. Lateral strip 126 is sealed to sealing material 134 in the closed upstream ends of the flow channels of filter element 44 c thereabove and is sealed to the closed upstream ends of the flow channels of filter element 44 d therebelow. Lateral sealing strip 124 , FIG. 15 , is sealed to sealing material 140 in the closed downstream ends of the flow channels of filter element 44 b thereabove and is sealed to sealing material 142 in the closed downstream ends of the flow channels of filter element 44 c therebelow. The described sealing protects the downstream, clean areas of the filter from the upstream, dirty areas of the filter.

In FIGS. 9-15 , the noted sealing layers are also provided by a right set of axially extending side edge layers 146 , 148 , 150 , etc., FIGS. 9 , 11 , 12 , 13 , 14 , and a left set of axially extending side edge layers 152 , 154 , 156 , etc. Each side edge layer of the right set extends axially from upstream end 52 to downstream end 54 and engages the right side of the filter element thereabove and the right side of the filter element therebelow such that the right side of the filter element is sealed to the right side of the filter element thereabove and to the right side of the filter element therebelow. Each side edge layer of the left set extends axially from upstream end 52 to downstream end 54 and engages the left side of the filter element thereabove and the left side of the filter element therebelow such that the left side of the filter element is sealed to the left side of the filter element thereabove and to the left side of the filter element therebelow. Side edge layers 148 and 154 are optional because of the sealing provided by downstream lateral sealing strip layer 124 . FIGS. 13 and 14 show deletion of side edge layers 148 and 154 . The noted lateral strip layers and side edge layers protect downstream and clean areas of the filter from the upstream and dirty areas of the filter. The noted strip layers and edge layers are preferably provided by adhesive such as hot melt, though other types of sealing strips may be used.

It is recognized that various equivalents, alternatives and modifications are possible within the scope of the appended claims.