FILTER ELEMENT WITH OUTLET PORT CHECK VALVE

An air cleaner is includes a housing defining an interior cavity, the housing having an inlet, a first outlet, and a second outlet. The air cleaner also includes a filter cartridge with a media arrangement extending between first and second end caps. In one aspect, the first end cap defines a first opening to the interior volume of the media arrangement and the second end cap defines a second opening to the interior volume of the media arrangement. In one aspect, the first opening has a dimension that is less than half a corresponding dimension of the second opening. The air cleaner can also include a valve arrangement in fluid communication with the first opening that allows airflow through the first opening in a first direction from the interior volume to the exterior side and prevents airflow through the first opening in a second direction from the exterior side into the interior volume.

TECHNICAL FIELD

The present invention relates to filter arrangements, typically for use in filtering air, such as intake air for internal combustion engines, and more particularly relates to filter assemblies that include multiple components arranged in a housing to provide desired filtering capabilities.

BACKGROUND

Air or other gas filtering is desirable in a number of systems. A typical application is in the filtration of intake air to internal combustion engines. Another is in the filtration of crankcase ventilation filter assemblies. Typically, such systems comprise filter assemblies having a serviceable filter cartridge therein. After a period of use, filter media within a filter housing requires servicing, either through cleaning or complete replacement. Typically, for an air cleaner or crankcase ventilation filter assembly used with an internal combustion engine, for example, on a vehicle, the filter media is contained in a removable and replaceable, i.e. serviceable, component, typically referred as a filter element or cartridge. In some applications, the air cleaner provides filtered air to other systems associated with the internal combustion engine and/or a vehicle driven by the internal combustion engine.

SUMMARY

An air cleaner is disclosed. The air cleaner can include a housing defining an interior cavity, the housing having an inlet, a first outlet, and a second outlet. The air cleaner also includes a filter cartridge. The air cleaner can also include a filter cartridge having a media arrangement defining an outer perimeter and an interior volume, and extending between a first end and a second end, the outer perimeter being in direct fluid communication with the housing inlet. The filter cartridge can also include a first end cap located proximate the media arrangement first end, the first end cap defining a first opening in fluid communication with the housing first outlet, and a second end cap located proximate the media arrangement second end, the second end cap defining a second opening generally circumscribed by a seal member forming a seal with the second outlet. In one aspect, the first opening has a dimension that is less than half a corresponding dimension of the second opening. The air cleaner can also include a valve arrangement in fluid communication with the first opening and the housing first outlet, the valve arrangement allows airflow through the first opening in a first direction from the interior volume to the exterior side and prevents airflow through the first opening in a second direction from the exterior side into the interior volume. In some examples, the valve arrangement is formed as part of the filter cartridge.

In some examples, the valve arrangement is a check valve biased into a closed position.

In some examples, the valve arrangement includes a deflectable stop member that deflects to allow airflow to flow in the first direction.

In some examples, the valve arrangement is in fluid communication with an internal passageway of a main body extending through the first opening.

In some examples, the valve arrangement is disposed within the internal passageway.

In some examples, the main body extends through the housing first outlet.

DETAILED DESCRIPTION

Herein, example filter assemblies, filter cartridges, features and components therefor are described and depicted. A variety of specific features and components are characterized in detail. Many can be applied to provide advantage. There is no specific requirement that the various individual features and components be applied in an overall assembly with all of the features and characteristics described, however, in order to provide for some benefit in accord with the present disclosure.

Referring toFIG. 1, a system10including an air cleaner assembly100is shown. In one aspect, the air cleaner assembly receives and filters ambient air12to provide clean, filtered air to the air intake of an internal combustion engine14and to an auxiliary system16that uses or requires a clean air source. In one example, the auxiliary system16is a compressed air system16. In one aspect, the air cleaner assembly100includes a housing102defining an interior cavity104. The housing102can be configured as a main housing106and a cover108that allow for the interior cavity104to be accessed when the cover108is removed from the housing106. The cover108can be secured to the housing106with connectors109using any number of methods or approaches known in the art, for example by over-center latches, interacting lugs, and the like. In one aspect, the housing102includes an inlet110for accepting raw, untreated air12, a first outlet112for discharging clean, filtered air to the intake of the internal combustion engine14, and a second outlet114for discharging clean, filtered air to an ancillary system, such as a compressed air system16.

Referring toFIG. 2, a filter cartridge200is shown within the internal cavity104of the housing102. The filter cartridge200converts the unfiltered air received at the inlet110to the clean, filtered air delivered to the outlets112and114. In a typical arrangement, the filter cartridge200is removably positioned within the air cleaner assembly interior cavity104, and would typically be considered to be a service component that is removable and replaceable, as desired and/or necessary. In one aspect, and as most easily seen atFIG. 3, the first filter cartridge200includes a media arrangement202having an exterior side204for receiving air from the inlet110and an interior passageway or volume207for delivering filtered air to the outlets112and114. In the example shown, the media arrangement202is tubular with a hollow interior and has a round cross-sectional shape. However, other shapes are possible, such as obround, oval, and rectangular cross-sectional shapes. In one aspect, the media pack202defines an outer perimeter208extending between a first end204and a second end206. In the example shown, the media arrangement202is formed from a pleated media construction. Suitable media constructions for the media arrangement202are discussed in more detail in the Media Types and Configurations section.

In one aspect, the filter cartridge includes a first end cap210positioned at the first end204of the media arrangement202. As configured, the first end cap210includes an end wall212that closes the first end204of the media arrangement202and also closes the interior volume207. The first end cap210is also shown as defining a port or opening212awithin the end wall212for receiving or defining an outlet arrangement214, discussed later. The filter cartridge200can also include a second end cap216positioned at the second end206of the media arrangement202. As configured, the second end cap216closes the second end206of the media arrangement202. In one aspect, the second end cap216defines an opening218circumscribed by a seal member220defining an inwardly directed seal surface220a. As most easily seen atFIG. 2, the seal surface220aforms a seal against an outer surface112aof the first outlet112, which can be characterized as an outlet tube. With such an arrangement, the seal member220may be characterized as an inwardly directed radial seal member. Other arrangements are possible, for example, the seal member220may be provided with an outwardly directed radial seal surface that forms against an outlet tube circumscribing the seal member220. With the disclosed configuration, all air entering inlet110is forced to pass through the media arrangement202before the air can be passed to the outlets112,114via the interior volume207.

The end caps210,216typically comprise a soft compressible material formed from foamed resin, such as a foamed polyurethane. Commercially available foaming polyurethane can be used for the end cap molded-in-place materials. A detailed description of usable polyurethane can be found in such prior art as WO 2006/026241, incorporated herein by reference. Other materials are possible.

The media pack can comprise only media or the media can be provided with an inner and/or outer liner before installation in the cartridge200. In some examples, an inner and/or outer liner is molded into the end caps210,216along with the ends of the media arrangement202.

As indicated previously, the filter cartridge200can be provided with an outlet arrangement214extending through the end wall212of the first end cap210. The outlet arrangement214can be formed integrally with the end cap210or can be separately formed and then inserted through the end wall212via the aperture212a. The outlet arrangement214is also shown as extending through the housing102at an aperture114. In some examples, a seal member115can be provided at the aperture114to minimize the infiltration of moisture and debris into the housing102. The outlet arrangement214can be directly or indirectly connected to a line18extending to the compressed air system16. For example, the outlet arrangement214can be connected to the line via an in-line connector which connects to the outlet arrangement214with a push-push type of action. The outlet arrangement214could also be connected directly to the line18via a clamping system. The outlet arrangement214could also be received into a structure provided on the housing102which is in turn coupled to the line18.

In one aspect, the outlet arrangement214includes a main body222and a valve assembly224. The main body222provides a passageway between the interior volume207of the filter cartridge200and the exterior of the filter cartridge200. The valve assembly224, in fluid communication with the main body222, operates to ensure that air can only flow in one direction through the main body222. This functionality ensures that clean air can flow to the auxiliary system16during normal operation, but will block flow in the reverse direction. In a failure mode, where a leak or break occurs somewhere between the outlet arrangement214and the auxiliary system16, the filter cartridge clean side (i.e. the interior volume207) is exposed to untreated ambient air via the leak or break. The presence of the valve assembly224ensures that this untreated ambient air is prevented from entering the filter cartridge clean side via the main body222. Were a valve assembly224not installed, a volume of untreated ambient air could undesirably bypass the filter media202through the outlet arrangement214and reach the internal combustion engine14via outlet112.

FIGS. 4 to 6show examples of the outlet arrangement214. The embodiments ofFIGS. 4 and 5both rely upon a biasing member, but are configured slightly differently and are oppositely acting. The embodiment ofFIG. 6utilizes a deflectable flap instead of a biasing member. As shown inFIGS. 4 and 5, the main body222extends from an inlet end222ato an outlet end222band is hollow to define an interior passageway222c. The inlet end222aextends into, or is at least in fluid communication with, the interior207of the filter cartridge200. Accordingly, clean air filtered by the cartridge200will flow into the inlet end222aof the main body222, through the interior passageway222c, and out of the outlet end222b, whereby clean air can be delivered to the auxiliary system16. In general, the dimension of the interior passageway222cprovided by the main body222is smaller than the dimension of the opening218in the second end cap216. For example, the interior passageway222ccan have a diameter that is less than half the diameter of the opening218, less than a quarter of the diameter of the opening218, less than an sixth of the diameter of the opening218, and/or less than an eighth of the opening218. Ultimately, the relative sizes of the passageway222cand opening218are a function of the airflow needs of the internal combustion engine14and the auxiliary system16, among other considerations.

In the examples shown atFIGS. 4 and 5, the valve assembly224is positioned within the interior passageway222cof the main body222and is configured as a biased check valve. In the exemplary embodiment depicted atFIGS. 4 and 5, the valve assembly224can generally include a biasing member224a, a stop member224b, a seat224c, and an end structure224d. The seat224cand end structure224dare configured with apertures or openings (i.e. formed as a grid structure, annular ring, or the like) such that airflow can pass through them. The biasing member224acan be a helical spring made of spring steel. In operation, the biasing member224aacts against the end structure224dand the stop member224bsuch that a seal is formed between the stop member224band the seat224c. Accordingly, any air flow in the direction from the end222btowards the end222awill be automatically blocked by the valve assembly224. However, with a sufficient pressure differential in the opposite direction, air flow from the end222ato the end222bwill be allowed as the biasing force of the biasing member224ais overcome by the air flow pressure differential. The valve assembly224can also be provided with a stop member with a deflectable flap or flange member that deflects to allow airflow in one direction but seats against the seat224cto prevent airflow in the opposite direction, thereby eliminating the need for a separate biasing member.

With reference toFIG. 6, a valve assembly224is provided that does not include a biasing member. Rather, the stop member224bis shaped as a disk and is deflectable relative to the seat224c. With such an arrangement, the valve assembly224is immobile with the exception of the deflectable stop member224b. When air is flowing in the first direction towards the outlet end222b, the stop member224bwill deflect in the direction of airflow (i.e. in a direction towards end222b) to allow air to flow through the passageway222cfrom the end222ato the end222b. However, when a pressure differential exists in the opposite direction, the seat224cprevents the stop member224bfrom deflecting towards the end222aand forms a seal with the stop member224bto prevent flow into the interior volume207.FIG. 6shows the valve assembly224with a portion of the stop member224bdeflected to allow airflow to pass through the valve assembly224.

Further arrangements and configurations are possible. For example, the valve assembly224could be connected to one of the ends222a,222bof the main body222, to the end cap210of the filter cartridge, or to the housing102. Also, the valve assembly224could be configured as a different type of valve, such as a solenoid valve that is actuated under predetermined conditions (e.g. pressure drop, reverse flow detected, etc.).

Media Types and Configurations

Any type of filter media can be used as the media pack for the filter cartridge200in accordance with embodiments of the invention. For example, woven and non-woven materials using natural and/or synthetic fibers can be used to form pleated media, fluted filter media, and depth media.

An exemplary configuration includes a filter cartridge with pleated media. An example of pleated media and end cap types usable with the air filter cartridge200disclosed herein is fully shown and described in U.S. Pat. No. 8,864,866, issued on Oct. 21, 2014, the entirety of which is incorporated by reference herein. The media can be configured in a cylindrical pattern as shown, if desired, although alternatives are possible. For example, the media can be somewhat conical in extension between the opposite ends. Also, the media can be configured with non-circular inner and/or outer perimeters; for example oval or other cross-sectional configurations are possible. When the media is pleated, the outer perimeter comprises outer pleat tips and inner perimeter comprises inner pleat tips. The media may include corrugations extending generally perpendicularly to the pleat tips, to facilitate keeping the pleats open during use. Various pleat tip folding techniques can be used to facilitate this, as are common in the art. Examples of this can be found in media packs the mark “PleatLoc” from Donaldson Company, Inc., of Minneapolis, Minn., the Assignee of the present disclosure. The media can also include hot melt media tip spacers or other media spacers if desired.

An exemplary configuration includes fluted filter media, such as a z-filter construction. The term “z- filter construction” as used herein, is meant to refer to a type of filter construction in which individual ones of corrugated, folded or otherwise formed filter flutes are used to define sets of longitudinal, typically parallel, inlet and outlet filter flutes for fluid flow through the media; the fluid flowing along the length of the flutes between opposite inlet and outlet flow ends (or flow faces) of the media. Some examples of filter media are provided in U.S. Pat. Nos. 5,820,646; 5,772,883; 5,902,364; 5,792,247; 5,895,574; 6,210,469; 6,190,432; 6,350,296; 6,179,890; 6,235,195; D399,944; D428,128; D396,098; D398,046; and D437,401, each of which is incorporated herein by reference.

It is noted that a plurality of embodiments are depicted and described. The embodiments are not meant to be exclusive with respect to features depicted. That is, selected features of one embodiment can be applied in one or more of the other embodiments if desired, to advantage. In many examples, the filter assembly depicted is an air cleaner assembly, for example, used to filter intake air for an internal combustion engine. Additional applications are possible, for example, applications in which the filter assembly is a crankcase ventilation filter assembly, in which the filter cartridge is used to filter crankcase blowby gases which include, typically, both particulate and liquid contaminant therein. Both type of filter assemblies are generally “gas filter assemblies,” since the carrier stage being filtered is gas (air or crankcase ventilation gases). While the techniques described herein will typically be used in application for gas filtration, they can be used in the filtration of other materials, for example, liquids, if desired.

The present invention has now been described with reference to several embodiments thereof. The entire disclosure of any patent or patent application identified herein is hereby incorporated by reference. The foregoing detailed description and examples have been given for clarity of understanding only. No unnecessary limitations are to be understood therefrom. It will be apparent to those skilled in the art that many changes can be made in the embodiments described without departing from the scope of the invention. Thus, the scope of the present invention should not be limited to the structures described herein, but only by the structures described by the language of the claims and the equivalents of those structures.